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Gas Turbine Operations-9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD
Siddhirganj, Bangladesh

Turbine 299249
Generator 270T888

2015

g
All rights reserved by the General Electric Company. No
copies permitted without the prior written consent of
the General Electric Company.

The text and the classroom instruction offered with it

are designed to acquaint students with generally
accepted good practice for the operation or main-
tenance of equipment and/or systems.

They do not purport to be complete nor are they

intended to be specific for the products of any
manufacturer, including those of the General Electric
Company; and the Company will not accept any
liability whatsoever for the work undertaken on the
basis of the text or classroom instruction. The
manufacturer’s operating and maintenance specifi-
cations are the only reliable guide in any specific
instance; and where they are not complete, the
manufacturer should be consulted.

The materials contained in this document are intended

for educational purposes only. This document does not
establish specifications, operating procedures or
maintenance methods for any of the products
referenced. Always refer to the official written
materials (labeling) provided with the product for
specifications, operating procedures and maintenance
requirements.

Proprietary Training Material Property of GE.

Use of these materials is limited to agents and GE
employees, or other parties expressly licensed by GE.
Unlicensed use is strictly prohibited.

© 2015 General Electric Company

 GE Power & Water

Gas Turbine Operations-9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD
Siddhirganj, Bangladesh
Turbine 299249
Generator 270T888
2015

Tab 1 Introduction
Course Description GT_Ops_Descr_10Day
Course Schedule 9FA_GF_Ops_10Day_Sched

Tab 2 Gas Turbine Description

MS9FA Gas Turbine Cross-Section 9FA UNIT _Crosssection
Gas Turbine Basics GT Basics _ 9FA_DLN2+_GF
Name Plate Data, Turbine-Gas Fuel (A004) 105T5589
Outline, Mechanical-Gas Turbine and Generator (0306) 105T6819
9FA Dual Fuel Piping Arrangement 9FA PIPING Overview
9FA Component Identification GT9FA_B00293Q-r0
9FA Component list GT9FA_B00293A-r0

Tab 3 Reference Documents

Gas Turbine Arrangement (ML 0406) 138E5399
Customer O&M Manual Users Guide GEK 116811
Technical Communications-Controls Connect GEK 103591
Connection and Line List, Customer Interface (4063) 145E4535
Diagram, GT Package Connection-Piping (0313) 107T6779
Diagram, GT Package Connection-Electrical 107T7998

Tab 4 Turbine Control Device System (ML0415)

Turbine Control Devices System Description GEK 116642
Schematic Diagram-PP Control Devices-Turbine (ML 0415) 143E2226
Instrumentation Arrangement, Unit (ML 0211) 112E6112

Tab 5 Inlet Filter and Exhaust System (ML 0471)

Inlet Compartment Arrangement-Air IFH_Pulse_GA_ETT
Schematic Diagram-PP Inlet & Exhaust Flow (ML 0471) 145E4540
Filter Control Panel (JB78) (GB00219836) 264B2554_1,2,5
Pulse Filtration System Sequence of Operations GB00219848
Screw Convertor A040_Screwcm_1,4

Exhaust Diverter Damper (073C)

Exhaust Stack-Bypass Damper Arrangement Exh_Div_Damper_Arr
Diverter Arrangement-Operations and Maintenance N045_Section1
Drawing-Damper Arrangement N045_Section 3_PARTIAL

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 1
 GE Power & Water

Tab 6 Instrument Air System (ML 0419)

Internal Arrangement Drawing (DIS-100-102-136) (1088760-
201) 411D1010
Schematic Diagram- PP Control Air (ML 0419) 143E2289
Air Processing Unit Description GEK 116681

Tab 7 Inlet Bleed (Air) Heating System (ML 0432)

Inlet Air Heating Simplified Diagram IAH Schem
0017HIE-Compressor Inlet Bleed Heat System (9FA) GEK 116865
Schematic Diagram-PP Inlet Air Heating (ML 0432) 145E4571
IBH Extraction Piping Arrangement (ML 0924) 119E9591
Inlet Air Heating Manifold Arrangement (ML A341) 106t2206

Tab 8 Performance Monitoring System (ML0492)

Performance Monitoring GEK 111323
Schematic Diagram-PP Performance Monitor (ML 0492) 146E4483

Tab 9 Lube Oil System (ML 0416)

Accessory Module General Arrangement 232D8032_1-6
FA Oil Systems Configuration FA-Oil-Systems-GF-r0
FA LO Simplified Schematic FA_LO_Schem-ME
Lubrication System Description GEK 111768
Schematic Diagram-PP Lube Oil (ML 0416) 145E4546
Lubrication Oil Piping Interconnect Arrangement (ML969A) 146E2636_1-4

Tab 10 Hydraulic / Lift Oil Supply (ML 0434)

FA Hydraulic Oil System Summary Schematics FA-Hyd-Sch-R1
Hydraulic Pump Pressure Compensators VPR3-PVG Oilgear Hyd Pump
Hydraulic Module HydModuleArr-r0
Hydraulic and Lift Oil System Description GEK 111787
Schematic Diagram-PP Hydraulic Oil Supply (ML 0434) 145E4545
0017HAE-Variable Inlet Guide Vane System GEK 106910
Inlet Guide Vanes IGV_Fund_04-2013
Variable Inlet Guide Vane Arrangement (ML 0811) VIGV_Arr
VIGV Actuator Simplified Schematic VIGV Hyd Schematic-Etrip
Servovalve Operations ST-GT_Servovalves_01-14

Tab 11 Fuel Gas System (ML 0422)

DLN 2-0+ Gas Fuel Systems Components DLN 2-0 GF Simple Sch
Fuel Gas Process System Drawing (0482) 207D3947
Fuel Gas Chromatograph Internal Arrangement (DIS-136)
(715990-136) 100V0133
4035-Fuel Gas Chromatograph System Drawing 145E4407
Gas Chromatograph for Fuel Gas GEK 111865

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 2
 GE Power & Water

0017HAE-Controls SSOV (Safety Shut off Valve) System

Testing GEK 116384
Accessory Module Fuel Gas System Components GCV+PA_Valves
Schematic Diagram-PP Fuel Gas (ML 0422) 145E4544
Dry Low Nox 2.0+ System Operation GEK 116535
DLN2.0+ Combustion Modes DLN2+Combustion Modes
Piping Arrangement-Fuel Gas (ML 0962) 100T6350
Fuel Nozzle End Cover & Casing Assembly-Gas Only
(ML0513) 141E7385TP
DLN 2+ GF Comb Cover DLN 2+GF Comb Cover
Fuel Nozzle End Cover Assembly-Gas (ML0513) 141E7384TP
DLN2+ Fuel Nozzle flow paths GT9FA_DLN2+Fuel Nozzle Flow Paths
0017CEE-Fuel Gas System-Gas Turbine Operational Best
Practices and Troubleshooting Guide GEK 116445

Tab 12 Gas Turbine Fuel Purge System (ML 0477)

Fuel Purge System Description GEK 110832
Schematic Diagram-PP Gas Turbine Fuel Purge (0477) 145E4554
Piping Arrangement-Purge Air (ML 0924) 139E7945
Tab 13 Cooling and Sealing Air System (ML 0417)
Cooling & Sealing Air-Summary Schematic Fa_Csa_Allflows
FA Compressor Arrangement 9F_Csa_Ejector_Schem
MS9FA Cooling & Sealing Air Flows GT9FA_9FACSA-R0
Cooling and Sealing Air System Description GEK 116682
Schematic Diagram-PP Cooling and Sealing Air (ML 0417) 145E4548
Cooling and Sealing Air Piping Arrangement (ML 0909) 100T7111
General Arrangement, 9FA Cooling Fan Module (DIS 100-
130-132) (020-0394) 232D7907_1

Exhaust Frame and #2 Bearing Cooling Air Piping (ML0972)

107T7375
Clearance Control Module General Arrangement 232D7890
CTM Impingement Cooling Air Piping Arrangement
(ML9019) 104T2780_1&6

Tab 14 Cooling Water System (ML 0420)

Cooling Water System Description GEK 110425
Schematic Diagram-PP Cooling Water (ML 0420) 145E4550

Tab 15 Heat and Ventilation System (ML 0436)

Ventilation and Heating System Description GEK 117015
Schematic Diagram-PP Heat and Ventilation (ML 0436) 145E4539

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 3
 GE Power & Water

Tab 16 Fire Protection System (ML 0426)

Fire Protection Skid-Outline and Foundation Drawings 288D1036_1
Fire Protection System Description GEK 111696
Schematic Diagram-PP Fire Protection (ML 0426) 145E4547
0017CJE-FM-200 Fire Protection System GEK 110891
Operation and Maintenance Manual / Fire Protection Skid 399A5169_FPSKID-OPS

Tab 17 Hazardous Gas Detection System (ML 0474)

0331-Outline, Hazardous Area Map-Gas Turbine and Load 107T5719
0017BTE-Aspirated Hazardous Gas Protection System GEK 117012
Schematic Diagram-PP Gas Detection (ML 0474) 103T1401
Installation Outline Drawing (DIS-102-112-113-120-130)
(3054-946) 108T0812
Outline, Hazardous Area Map-Model 324 Generator (C908,
0331) 124E8574
Panel, Dual Flow, Ultima XE (ATEX), Installation Outline E5JP_3054-1015
Panel, Single Flow, Ultima XE, (ATEX), Installation Outline E5JP_3054-1262

Tab 18 Compressor/Turbine Water Washing System

F Class Water Wash System Description GEK 111898
Schematic Diagram-PP Compressor Washing (ML 0442) 145E4542
0438-F-Class Gas Turbine Compressor Washing-Liquid
Washing Recommendations for Gas Turbines with Pulsed
Water Wash Systems GEK 111895
Water Wash Unit-General Arrangement and Piping Layout 232D8459_3
Cabinet Layout Water Wash 281B5885
Description-Water Wash Unit WWSKIDDESC

Tab 19 Starting System

0017CAE-Starting System GEK 107415
LS2100e Static Starter Product Description GEI 100792
Innovation Series LCI Liquid Cooling System GEH 6374
Assembly Turning Drawing TG_KoenigM392
Triple S Clutch GEN_FH2_SSS Clutch-r0

Tab 20 Excitation
Electrical One-Line Diagram (0444) 105T6628
Excitation System Schematic Ex2100e Functional
Excitation Fundamentals & EX2100 Overview EX21K OV_Siddhirganj
EX2100e and LS2100e Control Systems Touchscreen Local
Operator Interface Instruction Guide GEI 100787_pgs 1-27

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

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 GE Power & Water

Tab 21 Generator Construction

Hydrogen Generator Diagram 9FH2 Generator
Generator Description GEK 116371
Nameplate Data, Generator (B7F0) 105T6949
Generator Requisition Summary Sheets (C907) 105T9715
Generator Mechanical Outline (A1B0) 102T5239_1-2
Rotor Assembly RA001
End Shield Assembly 134E1123
GENERATOR CLOSE PIPING (G4J0) 102T5128
Ventilation Hydrogen Cooled Generator ST_STF11-7_9-12
IIBENG, IIBEXC-Shaft Grounding System, Operation and
Maintenance GEK116546a-9
IIBENG, IIBEXC-Collector and Carbon Brush Rigging
Installation, Operation and Maintenance ETTGEK116362_Pin
General Arrangement of 9FA GTE-LH Side Exit (63626346) 229D1756_6-9

Tab 22 Seal Oil System

Schematic Diagram-H2 and Seal Oil 145E4602
Shaft-Sealing System for Hydrogen Cooled Generator ST_STF11-14
Shaft Seaing Rings and Bearing Arrangement 2127124
IIBENG-Shaft Sealing System, H2 Cooled Unpackaged
Generator GEK 116742
Outline, Seal Oil Skid Generator Systems (G1C2) 135E3653
Outline Float Trap Arrangement (G1J2) 110E7151

Tab 23 Hydrogen and CO2 Gas Control

H2/CO2 System Simplified Schematics GEN_FH2_STF-11-26A-r0
Hydrogen & Carbon Dioxide Piping Manifolds (G1G0) (G2H0) 105T5012
IIBENG-Hydrogen and Carbon Dioxide Gas Control System-
Operation and Maintenance GEK103763
IIBACH-System Purging and Charging (Manual Purge) GEK 103611
IIBACH-Valve Positions During Normal Operation 2130754
LAB: Generator Purge Operations ST-GT_LabGenPurge_01-14
LAB: Normal MW Production Monitoring H2-in-Air ST-GT_LabNormOpH2inAir_01-14
Hydrogen Control Panel (HCP) Assembly Drawings (DIS-
102) (HD0357P01) 232D8994
Dual Hydrogen Control Panel (DHCP) (HA0385G03) (DIS-
201) 425A5454

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Electricity Generation Company of Bangladesh LTD 5
 GE Power & Water
Tab 24 SPEEDTRONIC Mark VIe Control
Functional Description GEK 107358
Assembly-Remote Control Systems (ML 4108) 106T5414_1-4
Fundamentals of Speedtronic-MK VIe Control Systems Fund_MK_Vie
OpFlex ETS Operational Overview OpFlex ETS Operational Overview-ETT
Human-Machine Interface (HMI)-Product Description GEI 100485
Workstation ST Alarm Mgmt Tools Workstation ST Alarm Mgmt Tools
Alarm Tracing Alarm Tracing_MKVIe_R1
Tab 25 Gas Turbine / Generator Operation
GT Product Safety GEK 111309
Unit Operation / Gas Turbine GEK 116689
Start Check Definitions StartCheck_9FA_GFl_TYPICAL_2014
Generator Prestart Checklist GEK 110608
Startup/Shutdown Sequence and Control GEK 111084
GT Startup Curve and Events GT Starting Events-SP
9FA SU_FSD curves with IBH 9FA SU5FSD curves
Synchronization GEK 116369
Loading Characteristics GEK 106866
Operation of Hydrogen Cooled Turbine Generators GEK 116772
Schematic Diagram-Load Equipment (0440) 106T7873
Generator Electrical Data (C902) 106T0341
Periodic Operational Inspections and Tests GEI 74478
Generator Alarms and Protection Recommendations GEK 75512-Tables 1, 2
0438-Basic Combined Cycle Start-up Procedure from a
Turbine Controls Point of View GEK 107538
0438-Heavy Duty Gas Turbine Operating and Maintenance
Considerations GER 3620
Tab 26 Controls Reference Documents
Device Summary (ML 0414) 399A4822
HMI Screens HMI Screens
This information will be provided during the
Alarm List course
Process Alarms - 9FA Non Site Specific Alarm Database
Tab 27 APPENDIX (This Information Provided Only On Separate CD)
Safety
Equipment Residual Risk Summary (Gas Turbine) (0124) 107T9923
Equipment Residual Risk Summary, Model 324 Generator
(C909) 383A2063
Equipment Residual Risk Summary, Electrical Equipment-
Generator (C912) 106T3876

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 6
GE Power & Water

Hazardous Gas
Outline, Hazardous Area Map-Gas Turbine and Load (0331) 107T5719
Notes, Hazardous Area Map (0331) 107T5718
Outline, Hazardous Area Map-A160/MS10 9FA Accessory
Module (0331) 141E8017
Outline, Hazardous Area Map-G023 Fuel Gas
Chromatograph (0331) 146E2561
Outline, Hazardous Area Map-Model 324 Generator (C908,
0331) 124E8574
Instruction Manual / Infrared Aspirated Gas Detection
System (DIS-201) 108T0826

Section 1-Custom Products Instruction Manual-Aspirated

Gas Detection System for Use In Gas Turbine Applications E5JP_Section 1
Section 2-Ultima X Gas Monitor Instruction Manual, MSA
Publication Number 10036101(FM) E5JP_Section 2
Section 3-Ultima X Gas Monitor Instruction Manual, MSA
Publication Number 10046690 (ATEX) E5JP_Section 3
Reference Documents
Gas Turbine Functional Description (MS9001FA, DLN-2+) GEK 110494
Combustion Chamber Arrangement (ML 0701) 123E9750TP
Gas Turbine Glossary of Terms C00023GT
GE Gas Turbine Performance Characteristics GER 3567
Gas Fuel Clean-Up System Design Considerations for GE
Heavy-Duty Gas Turbines GER 3942
IIBACH-Detection of Gas Leakage and Hydrogen Purity
Formulas GEK 117004
Specification, Schematics and P&ID's (0438) 372A3671
Specification, Piping & Instrumentation Diagram (P&ID)
(0438) 334A3032
Specification, P&ID Symbols and Nomenclature (0438) 213D1781
Plant Instrument Air System (replaces GEK 106689) (0438) GEK 110727
Controls
Specifications Settings-MKVI (ML A010) 100A1046
Mark VIe Turbine Control System-Product Description GEI 100600
OpFlex* Enhanced Transient Stability (ETS) for GE Gas
Turbines User Guide GEH 6810
Model-Based Control for GE Gas Turbines GEH 6740
Control System Toolbox for Configuring the Trend Recorder GEH 6408

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 7
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Excitation
Excitation Ex2100e Product Description GEI 100783

LCI Static Starter

LS2100e Static starter Control, User Guide GEH 6798
Schematic, LCI Cooling System Interconnecting Diagram
(4023) 361B5013

Gas Turbine Fluid Specifications

Lube Oil Recommendations-Turbine GEK 32568
Oil Recommendations-Generator GEK 116372
Process Specification-Fuel Gas GEI 41040
Cooling Water Requirement for Closed Systems GEI 41004

Gas Turbine Operations - 9FA.03 Gas Fuel DLN 2

Electricity Generation Company of Bangladesh LTD 8
Tab 1
GE Power and Water




Gas Turbine - Generator Operation Course

Course Description
This site-specific course is designed to enable, supervisors, operations, and
maintenance personnel to operate GE designed heavy-duty gas turbine generator
units. The course develops a background in gas turbine generator support systems,
and operations, which will enable participants to analyze operating problems and
take the necessary corrective action. It will also detail the design and construction
of the gas turbine generator.

Emphasis is placed on the detailed description of the gas turbine - generator major
components, the functions of their auxiliary systems, and the operator’s
responsibilities with regard to systems operations, and operational data
acquisition, and evaluation of anomalies thru the use of classroom instruction,
class exercises, and use of a turbine - generator trainer. If the course is held at the
customer’s location it will include site visits to familiarize personnel with the
physical layout of the gas turbine - generator, and the location of the various
system components, and provide personnel the opportunity to correlate the system
piping schematics to the respective system hardware. Operators are instructed in
how to interpret fault annunciation and how to determine if the annunciated fault
can be remedied by operator action or with the assistance of instrumentation
and/or maintenance personnel. The course focuses on the starting, loading, and
specific operator checks of the various turbine support and auxiliary systems to
ensure reliable operation of the gas turbine - generator unit, and the effect that
operation has on major mechanical maintenance.

g
_________________________________________________________________________GE Energy Learning Center

2 Week Gas Turbine Generator Operations Training Schedule

Gas Fuel

WEEK #1
Day 1 Day 2 Day 3 Day 4 Day 5
Gas Turbine Gas Turbine Systems Gas Turbine Systems Gas Turbine Systems Gas Turbine Systems
• Introduction • Cooling & Sealing Air • Lube Oil • DLN 2.6+ Combustion • Cooling Water
• Gas Turbine Theory & • Inlet Air Systems • Hydraulic / Lift Oil System • Heating & Ventilation
Construction • Exhaust Stack / Damper • Inlet Guide Vanes • Gas Fuel Systems • Fire Protection
• Operating Principles & • Inlet Air (Bleed) Heating • Trip Oil • Fuel Purge • Hazardous Gas
Performance • Performance Monitor • Compressor Water
• GT Instruction Books & Wash
Reference Drawings

WEEK #2
Day 6 Day 7 Day 8 Day 9 Day 10
Generator Electrical / Controls Controls Controls / Operations GTG Operations
Generator Excitation Mark VIe & HMI GT Control and GT and Generator
• Design & Construction • MK VIe General Hardware Protection Functions Operation & Protection
• Generator Devices Starting Means – and Software Overview
• Seal Oil LCI / Turning Gear GT Operation REVIEW
• Hydrogen System Turbine Devices
Electrical One Line HMI Screens
GT Control and Protection • User Defined Displays
Functions • Toolbox Overview

11/30/2014
Tab 2
 MS9001FA
Gas Turbine Assembly
Major Sections
COMBUSTION

FUEL GAS
LINER TRANSITION DIFFUSER
LIQUID FUEL PIECE
STEAM/WATER
INJECTION

VIGVS

ATOMIZING
AIR

GENERATOR

AIR INLET COMPRESSOR TURBINE EXHAUST

9FA UNIT
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9FA Gas Turbine Basics

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Function

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Fuel Combustion

2 3 Work
out
Compressor Turbine

1 4

Fresh Air Exhaust

gasses
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Flow COMBUSTION
14 Chambers
EXPANSION
AIR COMPRESSOR TURBINE EXHAUST
INLET 18 Stages 3 Stages
16.8:1 CPR

Power
Output

FORWARD
Base AFT

Shaft Rotation: Counter (anti) Clockwise – Viewed from Inlet

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Note: For instructional

purposes only

GAS
TURBINE
Temperature
and Pressure
Levels at
Base Load

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Typical Gas Turbine Cycle Conditions

Stage 1 Bucket Inlet Combustor Flame
(90-160 psi) (6.2 - 11 Bar) (140-245 psi) ( 9.5 – 17 Bar)
(2000-2600 F) (1090 - 1430 C (2400-3200 F) (1320 – 1760 C)
aka “Firing Temperature”” 4

Expand
Temperature

Burn
Exhaust Gas
(0.2-0.7 psi)
(1000-1200 F)
6 5
Compressor
3 Discharge
(150-260 psi) (10 – 17 Bar)
(650-800 F) (340 – 430 C)

Compressor
Inlet Compress
Face
2 1
Ambient 14.7PSIa 1Bar; 59F, 15C
Draw in Air

Pressure
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1st Row of Rotating

Blades

Inlet Struts

Compressor

Inlet Guide Vanes

Bellmouth (Open Position)

Inlet Guide Vanes

(Closed Position)

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Axial Compressor Arrangement

Compressor Rotor Blades

Compressor
Casings

Compressor Stator Vanes

Variable Inlet Guide Vanes

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Compressor Pressure Ratio

absolute compressor discharge pressure
Pressure Ratio =
absolute compressor inlet pressure

Absolute Pressure = gauge pressure + 14.7 PSIA

Example:
Inlet Pressure = - 0.60 psig
Discharge Pressure = 220 psig

PR = (220+14.7) / (- 0.60+14.7) = 264.7/ 14.1 = 16.65

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Compressor Protection:
1 Inlet Guide Vanes

2 Compressor Bleed Valves

3 Inlet Air (Bleed) Heating

4 Compressor Pressure Ratio Fuel Limitations

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______

___________

_________

_________
________

_______

_______ _________

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e Turbine Section (Hot Gas Path)

Buckets: 1st Stage 2nd Stage 3rd stage

_________________ _______ _______

1st Stage 2nd Stage 3rd stage

Nozzles __________________
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9FA Air Flows

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 GE Power Systems
e
#1 Journal and Thrust Bearing Assembly
Active Thrust Bearing Æ
Compressor --Æ

____________________ _________________

#1 Journal Bearing
________________

Rotor Thrust Collar (Runner)

Inactive Thrust Bearing
_________________________
_______________________
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 GE Power Systems
e
Tilting Pad Journal Bearing
Thermocouple
_______________

Lift Oil Port

______________

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 GE Power Systems
e
Thrust Bearing with Thermocouples

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e GE Power Systems

#2 Bearing Arrangement

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FACTORS AFFECTING

GAS TURBINE

PREFORMANCE

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15oC
101.35 KpaA (1.013 bar)

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400F(4.40C) Typical
limit when IBH anti-
icing comes on

Exhaust
Temp.

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e GE Power Systems

• Heat rate is the measure of heat energy in BTU’s of fuel

required to produce one kW-hr
• Heat rate is inversely proportional to unit efficiency
• The lower the Heat Rate, the better the performance of
the unit
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ISO Firing Temperature

• Reference Turbine Inlet Temperature

• A Calculated Temperature That Is
Not Physically Measured
• Always less Than Firing Temperature
as Defined by GE
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e GE Power Systems

9FA = 2400oF up to 3200oF

1320oC– 1760oC 9FA = 2420oF = 1327oC

GE Firing Temperature

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e GE Power Systems

Temperature Control Curve

Maximum Turbine Operating Temperatures
Design Process

Process Inputs: Process Output:

1) Current Cycle Design Isotherm

2) Target Firing Temperature

Exhaust Temperature
3) Expected Site Ambient
4) Expected Fuel
5) Target NOX
6) Exhaust Temperature (TX ) Limit
7) “Special” Considerations
- Humidity
- Dry vs Wet
- DLN TRISE Criteria
- Base Load vs Part Load
- Compressor Temp Bias
Compressor Discharge
Pressure

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VIGVs Affect Exhaust Temperature and Flow

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REFERENCE
FUEL

GER 3567H
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 GE Power Systems
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 GE Power Systems
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GER 3567H
Page 13

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Pressure Drop Effects – 9FA

% Effect on Effect on
Increase Output Heat Rate Exhaust Temp
10 mbar water – Inlet -1.19 0.21 0.7C (1.3 F)

10 mbar water – Exhaust -0.21 0.21 0.7C (1.3 F)

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e GE Power Systems

Note: For instructional purposes only

Effects of
Fouling
and/or
Damage on
Compressor
Performance

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GE Gas Turbine Design Philosophy

• Major Elements:
– Evolution of Designs,
– Use of Geometric Scaling,
– Thorough Preproduction Development,
– Use of Relatively Common Materials,
– Fuel Flexibility,
– Packaging,
– Maintenance

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END

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ML ITEM 0962 ML ITEM 0987 ML ITEM 0972 NO. 2 ML ITEM 0964 FIRE ML ITEM 0972 ML ITEM 0907
FUEL GAS PERFORMANCE BEARING COOLING PROTECTION EXHAUST FRAME COOLING NO. 2 BRG FEED & DRN
MONITORING

ML ITEM 0918
LIQUID FUEL ML ITEM 0924
PURGE AIR EXTRACTION
PURGE

ML ITEM 0965
ATOMIZING AIR
ML ITEM 0909
COOLING & SEALING AIR

ML ITEM 0953
COMPRESSOR
WATER WASH
ML ITEM 0976
EXH PLENUM DRN

ML ITEM 0905
NO. 1 BRG FEED
& DRN ML ITEM 0969
LUBE OIL FEED & DRN
INTERCONNECT

ML ITEM 0979 ML ITEM 0969

INLET PLENUM LIQUID FUEL PURGE
DRAIN INTERCONNECT

ML ITEM 0969
LIQUID FUEL
ML ITEM 0969 INTERCONNECT
LUBE OIL FEED
& DRN INTERCONNECT

ML ITEM 0906 ML ITEM 0969

LUBE OIL FEED ML ITEM 0961 ML ITEM 0968 ML ITEM 0915 / 0969 ML ITEM 0924 ML ITEM 0920 / 0969 ATOMIZING AIR
& DRN LOAD LIQUID FUEL WATER INJECTION COOLING WATER AIR EXTRACTION FALSE START DRN INTERCONNECT

9FA DUAL FUEL

PGU – SDA & BOP Overview
Dec. 13 ~ 15, 2005
 MS9001FA
Gas Turbine Assembly
Major Sections 10
7 6
12
13
8
ÒÒÒÒÒÒÒÒÒÒÒÒÒ 11
ÒÒÒÒÒÒÒ ÒÒÒÒÒÒ
ÒÒÒÒÒÒÒINÒÒÒÒÒÒ 9
AIR
17

ÒÒÒÒÒÒÒÒÒÒÒÒÒ 16
ÒÒÒÒÒÒÒÒÒÒÒÒÒ 5 15
ÒÒÒÒÒÒÒÒÒÒÒÒÒ ÒÒÒ
14 20 ÒÒÒ
EXHAUST

ÒÒÒ
STARTING
MOTOR &
TORQUE
19
CONVERTER

GENERATOR

18

1 2 3 4

B00293Q 1/94
 MS9001FA
Gas Turbine Components
1 – AIR INLET

2 – COMPRESSOR

3 – TURBINE

4 – EXHAUST

5 – VIGV’S

6 – FUEL GAS INLET

7 – LIQUID FUEL INLET

8 – STEAM / WATER INJECTION INLET

9 – ATOMIZING AIR INLET

10 – COMBUSTION

11 – LINER

12 – TRANSITION PIECE

13 – DIFFUSER

14 – 9th STAGE EXTRACTION

15 – 13th STAGE EXTRACTION

16 – 3rd STAGE NOZZLE

17 – 3rd STAGE BUCKET

18 – No. 1 BEARING

19 – No. 2 BEARING

20 – 17th STAGE INTERNAL EXTRACTION

BOO293A 1 / 99
Tab 3
DWG Number 138E5399 Rev A Released 3/19/2012

GE Proprietary Information - Class II (Internal)

US EAR - NLR
 g
GEK 116811a
Revised, October 2012
Grammatical Corrections Only

GE Energy

Customer O&M Manual Users Guide

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 GEK 116811a Customer O&M Manual Users Guide

TABLE OF CONTENTS

I.  MANUAL PURPOSE .................................................................................................................................. 4 

A.  General Information................................................................................................................................ 4 
B.  Timeline .................................................................................................................................................. 4 
C.  Translation .............................................................................................................................................. 4 
D.  Exclusions............................................................................................................................................... 4 
E.  Documentation Provided By Other Means ............................................................................................. 5 
F.  Proprietary Considerations ..................................................................................................................... 5 
G.  Responsibilities....................................................................................................................................... 5 
H.  Revision Process ..................................................................................................................................... 6 
II.  TYPICAL STRUCTURE AND CONTENTS OF THE CUSTOMER O&M MANUALS.................... 7 
A.  Manual Front Matter............................................................................................................................... 7 
1.  Letter ............................................................................................................................................... 7 
2.  GEK Number .................................................................................................................................. 7 
3.  Distribution List Section ................................................................................................................. 7 
4.  Revision History Section................................................................................................................. 7 
5.  Order Parts (Online Manual and CD’s only) .................................................................................. 8 
6.  Repair Solutions (Online Manual and CD’s only) .......................................................................... 8 
7.  Outage Optimizer (Online Manual and CD’s only) ........................................................................ 8 
8.  Main Table of Contents................................................................................................................... 8 
9.  Sub-supplier Equipment Cross Reference Index ............................................................................ 9 
B.  Gas Turbine Operation and Maintenance Manual ................................................................................ 10 
1.  Introduction................................................................................................................................... 10 
2.  Safety ............................................................................................................................................ 10 
3.  Gas Turbine................................................................................................................................... 10 
4.  Gas Turbine Auxiliary Systems .................................................................................................... 10 
5.  Gas Turbine Auxiliary System Modules....................................................................................... 11 
6.  Acoustic (Fabricated) Enclosures ................................................................................................. 11 
7.  Generator....................................................................................................................................... 11 
8.  Generator Auxiliary Systems ........................................................................................................ 11 
9.  Generator Excitation ..................................................................................................................... 12 
10.  Electrical Starting Means .............................................................................................................. 12 
11.  Electrical Energy Evacuation........................................................................................................ 12 
12.  Power Distribution System ........................................................................................................... 12 
13.  Control Equipment ........................................................................................................................ 12 
14.  Monitoring Equipment .................................................................................................................. 12 
15.  Technical Information Letters....................................................................................................... 13 
16.  Bills of Material and Drawings ..................................................................................................... 13 
C.  Steam Turbine Operation and Maintenance Manual ............................................................................ 13 
1.  Introduction................................................................................................................................... 13 
2.  Safety ............................................................................................................................................ 13 
3.  Operation....................................................................................................................................... 13 
4.  Control System.............................................................................................................................. 14 
5.  General Information ...................................................................................................................... 14 
6.  Turbine Maintenance .................................................................................................................... 14 
7.  Stationary Parts ............................................................................................................................. 14 
8.  Rotating Parts................................................................................................................................ 14 
9.  Steam Seal..................................................................................................................................... 14 
10.  Valves............................................................................................................................................ 15 

2 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Customer O&M Manual Users Guide GEK 116811a

11.  Bearings ........................................................................................................................................ 15 

12.  Turning Gear ................................................................................................................................. 15 
13.  Electrical ....................................................................................................................................... 15 
14.  Exhaust Hood Spray System......................................................................................................... 15 
15.  Lubrication .................................................................................................................................... 15 
16.  Hydraulic System .......................................................................................................................... 16 
17.  Monitoring .................................................................................................................................... 16 
18.  Supervisory Instruments................................................................................................................ 16 
19.  Generator....................................................................................................................................... 16 
20.  Generator Excitation ..................................................................................................................... 16 
21.  Generator Control Panel................................................................................................................ 16 
22.  Accessory Compartments.............................................................................................................. 16 
23.  Gas Control And Monitoring System ........................................................................................... 17 
24.  Seal Oil System ............................................................................................................................. 17 
25.  Technical Information Letters....................................................................................................... 17 
26.  Bills of Material and Drawings ..................................................................................................... 17 
III.  EXAMPLES FOR LOCATING INFORMATION ................................................................................. 18 
A.  Locating Component Tab ..................................................................................................................... 18 
B.  Locating Component within Tab .......................................................................................................... 19 
C.  Using the Bill of Materials and Drawings Tab ..................................................................................... 20 
1.  Bills of Material ............................................................................................................................ 20 
2.  Drawings ....................................................................................................................................... 21 
D.  Access to Online O&M Manuals.......................................................................................................... 21 
1.  Use this URL for an SSO ID request: ........................................................................................... 21 
2.  For direct access, the URL for the on-line Technical Manual application is:............................... 22 
E.  Fully Engineered Quote (FEQ)............................................................................................................. 22 

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

I. MANUAL PURPOSE

GE Energy provides a comprehensive set of Customer Operation and Maintenance Manuals (O&M
Manuals) as reference documentation to assist the final “User” in operating and maintaining the
equipment provided under the scope of the contract.

This document contains a brief description of the O&M Manual format and content, along with the
intended customer utilization of the Manuals.

A. General Information
The Customer O&M Manual set is organized to provide the User with important project-specific
reference information in addition to the User’s normal operation and maintenance procedures. Since
Operating and Maintenance philosophies vary from customer to customer, GE Energy does not
attempt to dictate specific procedures, but to provide basic limitations and requirements created by
the type of equipment provided. The information found in the Manuals is intended to build on a
User’s basic understanding of the operation and maintenance of complex equipment of this type. This
O&M Manual is not intended to be a step by step operational guideline. It is expected that if the
User needs additional assistance or further detail regarding their specific equipment, they should
consult directly with their local GE representative.

B. Timeline
Due to the variation in equipment supply scope and the complexity of the equipment being provided,
the O&M Manual documentation is established and published following the completion of the
engineering and manufacturing phase of each project. The Manuals are created based on a
standardized structure but developed to accurately reflect the actual equipment provided.

The intended timeline for Manual delivery is:

• The standard comprehensive set of O&M Manuals are generally provided in English twelve
(12) weeks following contract equipment ship date.
• The translated O&M Manual, when required, has its own delivery schedule, which is generally
17-23 weeks after the English O&M Manual is issued.
C. Translation
GE provides translated O&M Manuals as required by contract and/or local codes and standard
compliance requirements. Translation does not begin until after the English O&M Manual is
complete.

D. Exclusions
The Customer O&M Manual does not include documentation for and is not intended to be a guide
for:

• Partner Operation and Maintenance Manuals

• Engineering and Design
• Manufacturing
• Shipping
• Initial assembly and Installation
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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

• First commissioning
• Training
• Quality records

NOTE

GE Energy may provide specific detailed documentation in separate Manuals for

the subjects listed above.
E. Documentation Provided By Other Means
The following documentation is not included in the Customer O&M Manual, but may be provided by
GE Energy Services as necessary:

• Lists of Spare Parts for Ordering

The Customer O&M Manual is provided for the purpose of instructing the owner/operator in the
operation and maintenance of the equipment provided under the requisition scope of supply.
Information provided in the O&M Manual allows Users to locate and identify parts needed to
plan for and perform equipment maintenance.
The GE Energy Services parts organization is responsible for support required to either identify
or order spare or replacement parts and to provide recommended spare parts list as required.
• Dismantling at End of Service
The Customer O&M Manual does not contain information to accomplish complete plant
disassembly and provisions for long or short term storage after disassembly.
• Comprehensive Lubrication Program
The Customer O&M Manual does not provide a tailored lubrication program or list of specific
brand lubricants. However, the necessary lubrication requirements and lubricant specifications
for each system are provided in the appropriate system section of the O&M Manual. This
information is provided so that the owner/operator can integrate the lubrication requirements into
the overall plant maintenance program.
F. Proprietary Considerations
The following statement is found in every Customer O&M Manual:

“These instructions do not purport to cover all details or variations in equipment or to provide for
every possible contingency to be met in connection with installation, operation or maintenance.

Should further information be desired or should particular situations arise which are not covered
sufficiently for the purchaser’s purposes, the matter should be referred to the GE Company.”

G. Responsibilities
The Customer O&M Manuals are written for operators that already have a general understanding of
the requirements for safe operation of mechanical and electrical equipment in potentially hazardous
environments. They are not designed for use by personnel with little or no operational/maintenance
training or learned skills. Throughout the O&M Manual there are numerous references to model list
codes. These codes are taken directly from the GE Engineering Bill of Material for the turbine or
generator. For easier use of the O&M Manual, Users should have a general familiarity with the GE
Engineering Bill of Material and its structure.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

These instructions should be interpreted and applied in conjunction with sound engineering practice,
and in accordance with all provided safety guidelines. It is imperative that all safety rules and
regulations applicable at the site be followed to provide for safe operation of site equipment.

Because Operating and Maintenance philosophies vary from customer to customer, GE Energy does
not attempt to dictate specific procedures but to provide basic limitations and requirements created by
the type of equipment provided. The information provided in the Manuals is intended to build on a
user’s basic understanding of the operation and maintenance of complex equipment of this type. It is
expected that if the user needs additional assistance or further detail regarding their specific
equipment, they consult directly with their local GE representative.

The information set out in the O&M Manual set has been developed from GE Energy standard
equipment specifications. Where possible at the time of publication, modification information has
been included for that equipment which is specific to the contract and also for additional equipment
supplied by GE Energy which has been manufactured by others. The timing of publication and the
ongoing nature of design improvements may mean that features of the equipment supplied may be
different from those shown in this publication. No liability is accepted by GE Energy for errors, or
omissions or discrepancies of this nature.

No additional representations or warranties by GE Energy regarding the equipment or its use are
given or implied by the issue of the O&M Manual. The rights, obligations and liabilities of
GE Energy and the User are strictly limited to those expressly provided in the contract relating to the
supply of the equipment.

H. Revision Process
GE Energy makes the on-line (webbook) and optional hard copy/DVD O&M Manuals available to
the customer.

GE does not update the original set of Manuals except:

• To add documents that were not available and were listed as shortages when the Manual was
issued
• To correct an error or omission
• To reflect changes when an O&M Manual update is scheduled through Engineering (DCI/ECN)
• To update with as installed drawings (as applicable)
Revisions covered under separate contracts (FMI, CMU, etc.) will be issued in the form of a separate
addendum or as an update to the existing O&M Manual.

For the on-line version of the Customer O&M Manual, GE drawings and GE turbine-generator
publications are monitored for later revisions and updated to the latest revision on a regular basis. The
automated update process applies only to the on-line O&M Manual, it does not apply to DVD or
hardcopy sets. When an update is issued specifically for the hardcopy and/or DVD, a formal Revision
Instruction Sheet is issued to communicate specific instructions on where to insert, remove, or
replace the hardcopy documentation in each volume. This Revision Instruction Sheet is also included
on the updated DVDs.

The drawings in the Customer O&M Manuals are intended only to support the technical
documentation in the Manual, and do not constitute the official issuance of the drawings to the

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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

customer. It is the role of the as-built drawing file, officially transmitted to the customer apart from
the O&M Manuals, to reflect the installation modifications.

II. TYPICAL STRUCTURE AND CONTENTS OF THE CUSTOMER O&M MANUALS

The O&M Manuals are broken down by System, Sub System, MLI and then in some cases individual
components. The structure of any section is determined by the equipment discussed in the section and
content and level will vary to match equipment installed.

The following sections are a brief description of what is typically contained in the O&M Manuals.

A. Manual Front Matter

The following front matter material is contained in gas turbine and steam turbine O&M Manuals.

1. Letter

The letter section contains the letter delivered with initial delivery of the Manuals; it contains
date of delivery and initial instructions.

2. GEK Number

This section contains the Manual cover page.

3. Distribution List Section

The distribution list contains the following information:

• Date of last shipment

• Job or DM number
• Customer
• Equipment (Gas Turbine, Steam Turbine, Generator) serial numbers
• Station Name and Location
• Job Type (Combined Cycle, Simple Cycle, Etc)
• Who and where Manuals were shipped
• How many CD copies
• How many paper copies
4. Revision History Section

The Revision History contains the following information:

• Date of Revision
• Design Memo Number
• Customer
• Station Name
• Equipment (Gas Turbine, Steam Turbine, Generator) serial numbers
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 7
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

• Revision Number
• Update information (what was added , removed, or changed), along with why (Design
change number, As-built revision, Etc.) and the date of the change
5. Order Parts (Online Manual and CD’s only)

This section contains a link that will direct you to GE Parts Edge, which offers a comprehensive,
easy-to-use tool to access parts information and recommendations, as well as obtain quotes,
convert quotes to orders and track your orders in real-time from placement to delivery.

6. Repair Solutions (Online Manual and CD’s only)

This section contains a link that will direct you to GE Global Network of Repair Services where
you can:

• Locate a service center

• Request a quote for repair services
• Check the status of your repair
7. Outage Optimizer (Online Manual and CD’s only)

This section contains a link that will direct you to the Outage Optimizer which is designed to
replace the many loose papers and confusing forms that were once a necessary part of the outage
process, Outage Optimizer speeds planning, reduces quotation turnaround time and makes
collaboration with the service team much more convenient.

The Outage Optimizer tool allows you to:

• Review your technical data

• Review your update options to improve performance
• Benchmark your 7F, 9F or 7E Gas Turbine-generator performance
• Request a quote for repair services
8. Main Table of Contents

This section contains the Table of Contents for the Manual, which is broken down by tabs, and
sections within the tabs that are further broken down by Model List Items (MLI) or cost codes
(CC) and then to individual publications (component O&M Manuals, Drawings, Parts Lists,
Etc).

The Table of Contents functions as a broad general outline of the contents of the Manual set. It is
constructed as a generic tool to lead you to a main system. When you have located the system
you need, refer to the referenced tab number and volume.

NOTE

Throughout the O&M Manual there are numerous references to model list codes.
These codes are taken directly from the GE Engineering Bill of Material for the
turbine or generator. For easier use of the O&M Manual, Users should have a
general familiarity with the GE Engineering Bill of Material and its structure.

8 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

1. Typical Table Of Contents

9. Sub-supplier Equipment Cross Reference Index

This index contains the following information:

• MLI reference
• Tabs the MLIs are located in
• Description of the components or system contained in the MLIs
• GE drawing number for the MLI and or component
• Manufacturer or supplier of the components or systems

This section is provided to aid in component identification, while using the O&M Manuals.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

B. Gas Turbine Operation and Maintenance Manual

The following sections pertain to a typical gas turbine O&M Manual.

1. Introduction

This section contains the Customer O&M Manual Users Guide.

2. Safety

This section contains information to assist in the safe operation of the plant and may specifically
contain the following information:

• GE Product Safety Recommended Best Practices/Safe Site Work Practices

• Standard Noise Assessment Procedures
• Hazardous Areas
• Equipment Residual Risk Summaries
3. Gas Turbine

This section contains the following information for the gas turbine engine and the various
components that make up the Gas Turbine:

• Functional Description
• Performance Information
• Operation
• Settings, Device Summary, Control and Protection Articles
• Maintenance and Inspection Information
• Spare Parts Recommendations
• Standard Reference Documents Including Test Instructions And Fluid Specifications
• Component Information
4. Gas Turbine Auxiliary Systems

This section contains the system description, operation, maintenance, component and spare parts
reference information required to support gas turbine operation systems including, but not
limited to:

• Fuel Gas Systems

• Liquid Fuel Systems
• Atomizing Air
• Water Injection
• Diluent Injection Systems
• Purge Air System
• Cooling Water System

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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

• Cooling and Sealing Air System

• GT Ventilation System
• Lubrication System
• Hydraulic oil System
• Lift Oil System
• Trip Oil System
• Starting Means System
• Fire Protection System
• Hazardous Gas Detection System
• Performance Monitoring System
• Air Inlet System
• Inlet Air Heating
• Inlet Guide Vane System
• Water Wash System
• Inlet Temperature Suppression
5. Gas Turbine Auxiliary System Modules

This section contains the Auxiliary System Modules required to support gas turbine operation
systems including, but not limited to:

• Fuel Gas Module

• Accessory Module
• LF/AA Module
• Syngas Module
6. Acoustic (Fabricated) Enclosures

This section typically contains the gas turbine enclosure, load compartment, acoustical barrier,
and inlet and exhaust enclosure.

7. Generator

This section contains the generator operating and maintenance recommendations, and descriptive
GEK’s.

8. Generator Auxiliary Systems

This section contains the generator auxiliary system descriptions, operating and maintenance
GEK’s and P&ID’s for the Following Systems:

• Hydrogen Cooling System (if applicable)

• Seal Oil System (if applicable)

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 11
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

• Air Inlet Filters (if applicable)

9. Generator Excitation

This section contains the excitation control equipment, supporting transformer and compartment
information.

10. Electrical Starting Means

This section contains the LCI systems control equipment, supporting transformers and
compartments.

11. Electrical Energy Evacuation

This section contains the electrical components and enclosures including, but not limited to:

• Switchgear
• Bus Duct/Bus Accessory Compartment
• Generator Auxiliaries Compartment
• Generator Terminal Enclosure
• Transformers
• Neutral Ground
• GNAC/GLAC
12. Power Distribution System

This section contains the power distribution components including, but not limited to:

• Battery Chargers and Batteries

• Motor Control Centers
• Motor Starters
13. Control Equipment

This section contains the control Equipment components including, but not limited to:

• PEECC
• Turbine Control Panel
• Generator Control Panel
• Auxiliary Turbine Control Equipment
• Network and Operator Interface Equipment
14. Monitoring Equipment

This section contains the various monitoring equipment including, but not limited to:

• Vibration Monitoring

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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

• Hazardous Gas Monitoring System

• PDA Monitor
15. Technical Information Letters

Throughout the operational life of the equipment, GE Energy may periodically issue a Technical
Information Letter (TIL) to inform Users of new or changed information relating to the operation
or maintenance of equipment. In all cases, TIL documents are considered supplemental to
existing O&M Manual documentation.

This section contains a description of the Technical Information letter process. The appropriate
TILs are provided to customers when published.

16. Bills of Material and Drawings

The Bills of Material and Drawings Section (BOM&D) is designed to provide “project specific”
information in support of the documents contained in the O&M Manual. It contains the Bills of
Material (BOMs) and Assembly Drawings issued for each project as reference information for
field maintenance activities. Additional reference drawings may be included such as clearance,
nameplate and alignment drawings.

As an example, the BOM&D is used to locate and identify parts needed to plan for and perform
equipment maintenance, but it is not provided as the primary means for parts ordering.

GE has provided the Web based, electronic portal GE Parts Edge for parts ordering purposes.
You can access GE Parts Edge via GE's website or by selecting the “Order Parts” function
provided in the On-Line, as well as the CD version of the BOM&D If, after using these methods,
you need further parts assistance, contact your GE representative.

C. Steam Turbine Operation and Maintenance Manual

The following sections pertain to a typical steam turbine O&M Manual.

1. Introduction

This section contains the Customer O&M Manual Users Guide.

2. Safety

This section contains information to assist in the safe operation of the plant and may specifically
contain the following information:

• GE Product Safety Recommended Best Practices/Safe Site Work Practices

• Standard Noise Assessment Procedures
3. Operation

This section contains general information to for operation of the plant, which is contained in the
following sections:

• General - Literature, general in nature, on the operation of the turbine and generator
• Limits - Operational limits for safe operation of the turbine
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 13
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

• Precautions - Literature with component/system safety precautions during operation

• Prestart - Actions to be completed before starting the turbine
• Testing - Required testing of the steam turbine for continued safe operation
4. Control System

This section contains turbine control information, software testing associated with the control
system and turning gear control and operation.

5. General Information

This section contains general information that may include steam turbine device summary,
supplemental design data, steam turbine mechanical outline, and other general information as
required.

6. Turbine Maintenance

This section contains information on formulating a turbine maintenance program, recommended

turbine lubrication, cleaning requirements, some spare parts information and a fully engineered
Quote, which consists of GE Energy Services spare parts recommendations.

7. Stationary Parts

This section contains stationary components of the steam turbine including, but not limited to:

• Front Standard components

• Steam turbine joint hardware and tightening instructions
• Lifting devices
• Packing assemblies
• Special tooling
• Diaphragms
• Crossover piping
• Exhaust hoods
• Jacking devices
• Limits - Operational limits for safe operation of the turbine
8. Rotating Parts

This section contains rotating components of the steam turbine including, but not limited to:

• Rotor
• Couplings
9. Steam Seal

This section contains the steam sealing system components consisting of:

14 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

• Gland Exhauster System

• Regulating Valves
• Motor Operated Valves
• Manual Valves
• Piping and Instrumentation
10. Valves

This section contains the steam turbine control valves including, but not limited to:

• Main Steam Stop and Control

• Combined Reheat and Intercept
• Admission Stop and Control
• Reverse Flow Valve
• Equalizer Valve
11. Bearings

This section contains the steam turbine bearing drawings and reference documents.

12. Turning Gear

This section contains the steam turbine turning gear operation, service Manuals, and drawings.

13. Electrical

This section contains various drawings for the steam turbine electrical wiring connections to
electrical sensors and control components.

14. Exhaust Hood Spray System

This section contains the exhaust hood spray system components consisting of:

• Control Valves Assemblies

• Operating Documentation
• Piping and Instrumentation
15. Lubrication

This section contains the steam turbine lubrication system components consisting of:

• AC Motor Operated Lube and Hydraulic Pumps

• DC Motor Operated Pumps
• AC Motor Operated Vapor Extractors
• Lube Oil Conditioning System
• Filters

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 15
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

• Coolers
• Piping and Instrumentation
16. Hydraulic System

This section contains the steam turbine hydraulic system drawings, fluid recommendations O&M
Manual for components consisting of:

• AC Motor Operated Hydraulic Pumps Filters

• Coolers
• Piping and Instrumentation
17. Monitoring

This section contains the vibration monitoring, shaft voltage monitoring, and shell expansion
monitoring equipment.

18. Supervisory Instruments

This section contains steam turbine vibration monitoring probes and vibration monitoring O&M
Manual.

19. Generator

This section contains the generator operating recommendations, electrical and mechanical
drawings, descriptive GEK’s, and generator expected operating data.

20. Generator Excitation

This section contains the excitation control equipment, supporting transformer and compartment
information.

21. Generator Control Panel

This section contains the equipment included in the generator protection panel, which may
include, but is not limited to the following components:

• Various Relays
• Current Transformers
• Voltage Transformers
• Disconnect switches
• Alarm Panels
22. Accessory Compartments

This section contains the equipment required to support operation of the generator, which may
include, but are not limited to the following components:

• Various transformers

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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

• Excitation compartment
23. Gas Control and Monitoring System

This section contains the generator hydrogen cooling system drawings, monitoring equipment
and O&M Manual for components consisting of:

• Hydrogen Control Manifolds and Valves

• Hydrogen Monitoring Panel
• Piping and Instrumentation
24. Seal Oil System

This section contains the steam turbine seal oil system drawings, O&M Manual for components
consisting of:

• Hydrogen Seals
• Regulating Valves
• Piping and Instrumentation
25. Technical Information Letters

The Technical Information Letters Section is the same as defined in section 2.2.15

26. Bills of Material and Drawings

The Bills of Material and Drawings Section is the same as defined in section 2.2.16.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 17
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

III. EXAMPLES FOR LOCATING INFORMATION

A. Locating Component Tab
To locate information on your gas turbine’s main lube oil pump. First look in the volume Table of
Contents (found in the front of every volume) you will find that Lubrication System information is in
Tab 14 (this tab location for the Lubrication System may vary). Then turn to Tab 14 and look at the
Tab Table of Contents to find the instruction Manual for this pump.

The Table of Contents functions as a broad general outline of the contents of the Manual set. It is
constructed as a generic tool to lead you to a main system. When you have located the system you
need, refer to the referenced tab number and volume. Look for your item in the Tab Table of
Contents. Items will be listed by name and device symbol.

Main Table Of Contents

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without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

B. Locating Component within Tab

The Tab Table of Contents is a precise, specific list of all documentation included in a particular tab.
The Tab Table of Contents for any turbine system, like the Lubrication System in our example above,
will always list the system text first, followed by the system schematic. Following this information is
an item number arranged list of all major devices (filters, motors, pumps, etc.) and their publication
number. These publications can be found directly behind the Tab Table of Contents.

If you needed to find information on the lube oil pump, the main Table of Contents would have
directed you to the correct number tab. From the Tab Table of Contents you can look down the list of
devices, locate the entry entitled “Main AC Lube Oil Pump Assembly,” and see that Buffalo Forge
publication “Buff Pumps_3382GE-Heb” covers this pump. This publication can be found in this tab.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 19
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

C. Using the Bill of Materials and Drawings Tab

This section contains bills of materials and drawings.

1. Bills of Material

The Bills of Material and Drawings Section (BOM&D) is designed to provide “project specific”
information in support of the documents contained in the O&M Manual. It contains the Bills of
Material (BOMs) and Assembly Drawings issued for each project as reference information for
field maintenance activities. As an example, the BOM&D is used to locate and identify parts
needed to plan for and perform equipment maintenance. This Bill of Materials has Part number
10 Highlighted.

20 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

2. Drawings

The Tag number corresponds to a number, which identifies the component on the drawing, in
this case the number 10, for part number 10.

D. Access to Online O&M Manuals

The O&M Manual may also be accessed on-line at www.gepower.com, under Technical Library
select “Technical Manuals”. CD/DVD and/or hardcopy formats are also provided depending on
contractual requirements.

To access the on-line version you must first obtain a Single Sign On ID (SSO ID). The URL address
in item 1 provides the link to request an SSO ID. The URL address in item 2 provides the link to the
online Technical Manual application.

1. Use this URL for an SSO ID request:

http://www.gepower.com/online_tools/downloads/how_to_register_SSO.pdf

http://www.gepower.com/about/suppliers/en/index.htm
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 21
without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

2. For direct access, the URL for the on-line Technical Manual application is:

http://www.gepower.com/online_tools/tech_manuals.htm.

E. Fully Engineered Quote (FEQ)

GE Energy Services has provided to the owner/operator, under separate cover, a “Spare Parts
Recommendation” including price and delivery cycle data for this project. That listing was provided
to allow the equipment owner/operator to select specific spare parts to be provided by GE.

The GE Energy Services Spare Parts Recommendation included in the GE O&M Manuals is a
coordinated listing, however not including pricing or delivery cycle data. This “coordinated copy” of
the original Spare Parts Recommendation from GE Energy Services is titled “Spare Parts
Recommendation (Not priced)” and is provided for reference only. It can be used in conjunction with
maintenance activities described in the GE O&M Manuals.

This Spare Parts Recommendation is based on the AS SHIPPED configuration of the unit(s). Any
changes made to the unit(s) after shipment are NOT reflected. For Material Ship Direct (MSD) items
listed in the section labeled “MSD Waiting Definition”, the spare parts lists were not available at the
time the GE Energy Services Spare Parts Recommendation was prepared. For those items, Users can
refer to the appropriate tab in the O&M volume of the comprehensive set of GE O&M Manuals.

For additional questions related to Spare Parts contact your local GE Representative.

The Fully Engineered Quote (FEQ) is the GE Energy Services Spare Parts Recommendations, for
either the gas turbine and generator or the steam turbine and generator. For the steam turbine it is
located in the turbine maintenance section, for the gas turbine it is located in the gas turbine section.

22 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Customer O&M Manual Users Guide GEK 116811a

THIS PAGE INTENTIONALLY LEFT BLANK

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without prior permission of the copyright owner.
GEK 116811a Customer O&M Manual Users Guide

g GE Energy
General Electric Company
www.ge-energy.com

24 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 g
GEK 103591c
Revised, May 2012

GE Energy

Technical Communications

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 103591c Technical Communications

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Technical Communications GEK 103591c

TABLE OF CONTENTS

I. GENERAL ................................................................................................................................................... 4
II. SELF SERVICE AND CONTROLS CONNECT INSTRUCTIONS ..................................................... 5

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.
GEK 103591c Technical Communications

I. GENERAL

Technical communications are issued periodically to GE turbine and generator users and service
personnel to provide updated information on the operation and maintenance of the GE supplied
equipment. These communications include Technical Information Letters (TILs) and are GE’s way of
telling their customers about technical improvements, maintenance practices, or safety concerns
regarding GE supplied equipment.

Many of GE’s customers prefer to have TILs that affect their units directly emailed to them. GE
maintains a database of these customers’ email addresses and the appropriate TILs are emailed to the
customers when published. TIL distribution will be made by electronic email distribution.

Equipment owners will need to register for TIL distribution via Self Service or Controls Connect page at
www.ge-energy.com. A direct link to the Controls Connect and Self Service website is provided below.

http://www.ge-energy.com/tools_and_training/tools/controls_connect.jsp

Detailed instructions on how to register and utilize this new functionality are included in the pages that
follow.

GE is committed to providing every customer with the TILs that affect their sites. When a TIL is issued
that affects your turbine or generator, that TIL is promptly emailed to the address listed for that unit that
is contained in the GE database. Information provided as part of the Technical Communications
registration will be used for the process of distributing TILs and will be stored on a secure server in
compliance with GE Energy data storage policy.

4 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Technical Communications GEK 103591c

II. SELF SERVICE AND CONTROLS CONNECT INSTRUCTIONS

Self Service and Controls Connect is accessed through http://www.ge-energy.com/ or directly though
the link below:

http://www.ge-energy.com/tools_and_training/tools/controls_connect.jsp

Self Service and Controls Connect requires an SSO login in order to access the application. Once at this
page, you will need to login with your SSO or register for an SSO if you do not have one.

Accept the Legal Notices by selecting OK

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
without prior permission of the copyright owner.
GEK 103591c Technical Communications

Self Service landing page

Viewing TILs

In order to view your unit specific TILs, you will need to associate at least one site to your profile. Select
My Profile. TILs are associated to sites and you will need to add sites using the available sites tab. For
best results, search by unit serial number. You will only be able to see sites that are associated to your
SSO.

NOTE

TIL search may also return TILs with “Obsolete” status. These TILs have either
been superseded by a revision, or made obsolete by Product Service.
6 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Technical Communications GEK 103591c

Once a site is associated to My Profile, it will show up under My Sites. If multiple sites are selected,
technical communications from all the sites will return in the knowledge management section of the Self
Service tool.

Select Home to return to the Self Service landing page. TILs can be viewed via two methods:

Method 1

1. Enter the TIL number into the search bar and select search
2. The knowledge base will return the TIL document as well as all knowledge objects referencing that
content. Alternately, a topic can be searched with the term TIL in the search bar and related TILs to
that topic that will return. Only TILs applicable to the sites in your profile will return. If no sites
are associated, no TILs will return.

TIL 1725 – TIL Distribution

3. By selecting My TILs in the content areas in the center of the page, TILs can be browsed that are
applicable to the site(s) in My Profile.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 7
without prior permission of the copyright owner.
GEK 103591c Technical Communications

Method 2

1. Select the Technical Communications link under the Related Tools menu on the right side of the
webpage.
2. Pick one of the three searches:

a. Searching by TIL number will return a list of TILs that meet that criterion. You can then select a
TIL number and see the units which the TIL applies to.

b. Searching by unit serial number will return the TILs that apply to that unit

c. Searching by the search criteria will return TILs that meet the searched upon criteria.

Registering for TILs

TIL distribution will be made by electronic email distribution. Equipment users will need to register for
TIL distribution via Self Service or Controls Connect by selecting the Technical Communications link
under the Related Tools menu on the right side of the webpage.

1. Select the Technical Communications link under the Related Tools menu on the right side of the
webpage.
2. Select the TIL Registration link in the header bar

8 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Technical Communications GEK 103591c

3. Search by the desired method to see the site you wish to register with. You will only be able to see
sites associated with your SSO.

a. Searching by Customer and Site Station Name will take you to that site

b. Searching by Unit Serial # will show a list of email addresses against that serial number

c. Searching by Email Address will show you all the units associated with that email address.

4. Update the distribution information by:

a. Selecting Add New User

b. Adding or removing units and selecting Update

c. Selecting the check box and selecting Delete

i. You will only be able to delete your individual profile

ii. Contact a GE representative to update other profile information.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
GEK 103591c Technical Communications

Knowledge Base

The Knowledge Base is a continually evolving resource which contains information from the technical
manuals, TILs, FAQs and other GE content. We are continually adding and updating content to the
system. The Knowledge Base is intended to provide GE customers and internal personnel with
instantaneous access to information about their equipment.

You have the option to switch your edition back and forth between Controls Connect and Self-Service
micro sites. This feature is available on the home page of the web site only. Self-Service includes all the
content within Controls content but also contains content that covers GE Gas Turbines, Steam Turbines
and Generators.

Controls Connect is a micro site specifically dedicated to delivered a tailored service experience for GE
Controls products and services. The content is filtered to be Controls product content relevant allowing
the user to see only Controls product content.

g GE Energy
General Electric Company
www.ge-energy.com

10 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
DWG Number 145E4535 Rev B Released 8/8/2013 Page 1 of 4

8 7 6 5 4 3 2 SIZE

E
DWG. NO.

145E4535
SH.

1
REV.

B 1
REVISIONS
THIS DOCUMENT SHALL BE
NOTES: NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
SHEETS OF THIS DOCUMENT SH1: UPDATED NOTES 20 AND 25. SH2 AND
1 THE TERM “OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT 25 AT FG1 START-UP MODE GAS TEMPERATURE ARE THE SAME REVISION SH3: UPDATED MAXIMUM TEMPERATURE
DESIGNER AND/OR PLANT INSTALLER. MAX: 350°F [177°C] MLI 0477 LEVEL AS INDICATED. FOR FG1/FG20 AND MIN/MAX TEMPERATURE
2 DATA CELLS POPULATED WITH THREE DASHES (---) INDICATE THAT THIS FIELD MIN: 50°F [10°C] SUPERHEAT FOR FG21/FG425/FG426/FG428 A&B/FG438/ 12-12-17 SEE PLM
A
IS NOT APPLICABLE TO THE FLUID TYPE OR CONNECTION. FG439. SH4: REVISION LEVEL UPDATE ONLY
3 UNITS ARE AS SPECIFIED IN COLUMN HEADING UNLESS OTHERWISE SPECIFIED NORMAL OPERATING GAS TEMPERATURE: 295°F [146°C] - NO CHANGE.
50 THIS CONNECTION IS A POTENTIAL SOURCE OF FLAMMABLE ATMOSPHERE. ECR0019317
WITHIN A CELL. THE EXTENT OF THE HAZARDOUS AREA AND OTHER INFORMATION AND
MIN SUPERHEAT TEMPERATURE MUST COMPLY WITH THE REQUIREMENTS ECO0085113 LIÑAN, CLAUDIA
H MLI 0416 STATED IN GEI 41040. THE MAXIMUM RATE OF GAS TEMPERATURE CHANGE IS RECOMMENDATIONS TO ASSIST OTHERS ARE GIVEN IN MLI 0331.
SH1,2 & 3: REVISION LEVEL UPDATE ONLY.
H
2 F/SEC [1.1 C/SEC]. SH4: ADDED CONNECTIONS WW121 &
4 LO19 IS A LUBE MIST VENT MOUNTED ON THE ROOF OF THE A160 MODULE AND
WW122
REQUIRES NO INTERFACE BY OTHERS. HOWEVER, THIS CONNECTION IS A STARTUP AND OPERATION IN DIFFUSION MODE - DIFFUSION NOZZLE ONLY. MLI 4035 B 13-08-07 SEE PLM
ECR0030642
POTENTIAL SOURCE OF FLAMMABLE ATMOSPHERE. THE EXTENT OF THE EITHER HEATED OR UNHEATED FUEL MAY BE USED. IF FUEL HEATING
51 REFER TO MLI 0331, HAZARDOUS AREA MAP AND NOTES FOR INFORMATION ON ECO0114464
HAZARDOUS AREA AND OTHER INFORMATION AND RECOMMENDATIONS TO BECOMES UNAVAILABLE, THE UNIT OPERATION ABOVE DIFFUSION MODE P.SANTHIYAGU
ASSIST OTHERS IS GIVEN IN MLI 0331. HAZARDOUS AREAS AND RATINGS OF GE SUPPLIED EQUIPMENT. IT IS THE
POTENTIALLY WILL BE LIMITED BY LOAD OUTPUT, COMBUSTOR DYNAMICS, OR
RESPONSIBILITY OF OTHERS TO CARRY OUT ANY NECESSARY FURTHER
MLI 0417 EMISSIONS.
POWER PLANT HAZARDOUS AREA CLASSIFICATION STUDIES AND TO DESIGN
AND INSTALL THE PIPING AND EQUIPMENT IN ACCORDANCE WITH APPLICABLE
5 INSTRUMENT AIR MUST BE PROVIDED IN ACCORDANCE WITH INSTRUMENT AIR 26 PRESSURE REGULATION AND CONTROL AT FG1: SAFETY CODES AND STANDARDS. GUIDANCE AND INFORMATION IS GIVEN IN
REQUIREMENTS INCLUDED IN MLI 0438 AND SIZED CONSIDERING THE
MLI 0331 TO ASSIST OTHERS IN THIS TASK.
FOLLOWING CONDITIONS: -DURING TURBINE OPERATION FUEL GAS PRESSURE TO BE REGULATED
A) TURBINE START-UP CONDITION: BETWEEN 410 PSIG [2830 KPAG] AND 500 PSIG [3450 KPAG].
-TRANSIENT: NO FLOW -STEADY-STATE: SUPPLY PRESSURE AT ANY OPERATING POINT WITHIN THE
-STEADY STATE: NO FLOW GAS TURBINE CAPABILITY MUST BE REGULATED WITHIN +/- 1% OF POINT, WITH
B) TURBINE OPERATION CONDITION (FULL SPEED, NO LOAD): PEAK-TO-PEAK PERIOD OF NOT LESS THAN 8 SECONDS (0.25% PER SECOND
-TRANSIENT: FLOW REQUIRED WHEN MAIN BREAKER IS CLOSED. AVERAGE RATE OF CHANGE).
AIR IS NEEDED FOR ONLY 5 SECONDS.
G -STEADY STATE: NO FLOW
-TRANSIENT: DURING TRANSIENTS MAXIMUM SUPPLY PRESSURE EXCURSIONS
MUST NOT EXCEED EITHER A 1% PER SECOND RAMP OR 5% STEP. THE 1% PER
G
C) TURBINE SHUT DOWN CONDITION: SECOND RAMP LIMIT IS APPLICABLE OVER THE RANGE OF MINIMUM REQUIRED
-TRANSIENT: NO FLOW PRESSURE TO MAXIMUM OPERATION PRESSURE. THE 5% STEP LIMIT IS
-STEADY STATE: NO FLOW APPLICABLE OVER THE RANGE OF MINIMUM REQUIRED PRESSURE TO 95% OF
6 THE DESIGN PRESSURES AND TEMPERATURES ARE THE CONDITIONS MAXIMUM OPERATING PRESSURE AND WITH NO MORE THAN ONE 5% STEP
UPSTREAM OF THE ISOLATION VALVES. PIPING DOWNSTREAM OF CLOSED CHANGE IN 5 SECONDS. THESE TRANSIENT LIMITS APPLY DURING BRIEF
ISOLATION VALVES WILL NOT NORMALLY BE SUBJECTED TO THESE PERIODS ASSOCIATED WITH PRESSURE CONTROL MODE TRANSFERS SUCH AS
CONDITIONS. THESE VALVES MUST ONLY BE OPEN DURING AN OFF-LINE BETWEEN GAS FUEL PRESSURE SOURCE CHANGEOVERS, OR RAPID FUEL
WATER WASH. PIPING AT THESE CONNECTION POINTS MUST BE DESIGNED TO DEMAND TRANSIENTS SUCH AS GAS TURBINE LOAD REJECTIONS.
THE DESIGN PRESSURE LISTED IN CASE A VALVE IS LEFT IN THE OPEN
POSITION. 27 INSTRUMENT AIR TO BE SUPPLIED BY OTHERS, MUST BE IN ACCORDANCE
7 DESIGN PRESSURE AND TEMPERATURE VALUES DO NOT OCCUR AT THE SAME WITH GEK 110727, (MLI 0438). AIR SUPPLY REQUIRED TO BE SUPPLIED PRIOR
TIME DURING UNIT OPERATION. DESIGN PRESSURE WILL OCCUR WHEN THE TO STARTUP OF TURBINE. DESIGN FLOW IS 0.04 PPS [0.02 KG/S] 10 SECONDS
TEMPERATURE IS 647°F [342°C]. DESIGN TEMPERATURE WILL OCCUR WHEN TRANSIENT AND 0.01 PPS [0.006 KG/S] STEADY STATE. MINIMUM PRESSURE IS
THE PRESSURE IS 186 PSIG [1280 KPAG]. 90 PSIG [620 KPAG].
8 CA52 DESIGN PRESSURE AND TEMPERATURE VALUES DO NOT OCCUR AT THE 28 MINIMUM PRESSURE AT FG21 IS BASED ON DOWNSTREAM FUEL GAS
SAME TIME DURING UNIT OPERATION. DESIGN PRESSURE WILL OCCUR WHEN CONDITIONING EQUIPMENT AND ASSUMED INTERCONNECT PIPING PRESSURE
F THE TEMPERATURE IS 463°F [240°C]. DESIGN TEMPERATURE WILL OCCUR
WHEN THE PRESSURE IS 66 PSIG [455 KPAG].
LOSSES AT THE MAXIMUM FLOW RATE BETWEEN FG21 AND FG1. ACTUAL F
PIPING PRESSURE LOSSES BETWEEN FG21 AND FG1 MUST BE DEFINED AND
9 CA53 DESIGN PRESSURE AND TEMPERATURE VALUES DO NOT OCCUR AT THE ACCOUNTED FOR BY OTHERS. REFER TO MLI 0482 FOR A LIST OF ADDITIONAL
SAME TIME DURING UNIT OPERATION. DESIGN PRESSURE WILL OCCUR WHEN DOWNSTREAM EQUIPMENT.
THE TEMPERATURE IS 463°F [240°C]. DESIGN TEMPERATURE WILL OCCUR
WHEN THE PRESSURE IS 115 PSIG [793 KPAG]. MLI 0426

MLI 0419 29 DESIGN FLOW RANGE BASED ON MINIMUM AND MAXIMUM FIELD RANGE
EQUIVALENT LENGTHS. INTERCONNECT PIPING MUST BE DESIGNED PER THE
10 ALLOWABLE PRESSURE DROP IN THE INTERCONNECT PIPING BY OTHERS IS INTERCONNECT PIPING DATA TABLE ON MLI 0426 DRAWING.
LESS THAN OR EQUAL TO 10 PSID [68.9 KPAD]. 30 THE FLOW RATE THROUGH MANIFOLD CONNECTIONS NN7 AND NN8 IS BASED
ON THE CAPACITY OF THE CO2 TANKER FILLING PUMP. FLOW RATE NORMALLY
MLI 0420
RANGES FROM 44.1 TO 51.5 PPS [20.0 TO 23.4 KG/S] FOR NN7 AND 0.076 TO
11 GE SUPPLIED EQUIPMENT PRESSURE DROPS: 0.089 PPS [0.034 TO 0.040 KG/S] FOR NN8. THE FILLING PRESSURE TYPICALLY
COOLING WATER LOCATION PRESSURE DROP RANGES FROM 220 TO 250 PSIG [1520 TO 1720 KPAG] . THE VAPOR
LUBE OIL COOLER (CW6 -CW7) 20 PSID [138 KPAD] CONNECTION NN8 MUST RETURN A VOLUME OF VAPOR EQUIVALENT TO THE
GENERATOR (CW12 - CW13) 8 PSID [55.2 KPAD] VOLUME OF LIQUID PUT INTO THE TANK.
TURBINE BASE (CW52 - CW53) 20 PSID [138 KPAD] 31 THE CO2 STORAGE SYSTEM IS A VENDOR DESIGNED SKID MOUNTED SUPPLY
LCI COOLER (CW94 - CW95) 4.7 PSID [32.4 KPAD] AND DISTRIBUTION SYSTEM WITH A CAPACITY OF 12000 LB [5440 KG]. PIPING
E DETAILS ARE GENERIC AND CAN VARY BASED ON SUPPLIER DESIGN. SYSTEM E
12 GAS TURBINE HEAT REJECTION: DESIGN PRESSURE AND TEMPERATURE IS 325 PSIG[2240 KPAG].
COOLING WATER LOCATION HEAT REJECTION 32 DESIGN CONDITIONS DO NOT OCCUR AT THE SAME TIME. DESIGN
BTU/MIN [KW] TEMPERATURE OCCURS AT 14.7 PSIG [101 KPAG], WHILE DESIGN PRESSURE
TURBINE BASE (CW52 - CW53) 500 [8.78] AND FLOW OCCUR AT 60°F [15.6°C].
LUBE OIL COOLER (CW6 - CW7) 145000 [2550]
LCI COOLER (CW94 - CW95) 5800 [102] MLI 0432

33 DESIGN PRESSURE AND TEMPERATURE VALUES ARE NOT CONCURRENT

13 GENERATOR HEAT LOADS: OPERATING VALUES. DESIGN PRESSURE WILL OCCUR WHEN THE
GENERATOR HEAT REJECTION TEMPERATURE IS 647°F [342°C]. DESIGN TEMPERATURE WILL OCCUR WHEN
COOLANT INLET TEMPERATURE (CW12 - CW13, ALL COOLERS) THE PRESSURE IS 186 PSIG [1280 KPAG].
BTU/MIN [KW]
79°F [26°C] 161000 [2830] MLI 0442
104°F [40°C] 139000 [2450]
34 WATER WASH NORMAL OPERATING CONDITIONS AS FOLLOWS:
115°F [46°C] 119000 [2090]
OFF-LINE: NORMAL PRESSURE = 95 PSIG [655 KPAG]
NORMAL TEMPERATURE = 50 TO 180°F [10 TO 82.2°C]
14 COOLANT SYSTEM EQUIPMENT IS DESIGNED TO OPERATE WITH THE FLOW RATE = 58.5 USGPM [221 LPM]
D FOLLOWING COOLANT:
100% WATER WITH ADDITIVES
ONLINE: NORMAL PRESSURE = 90 PSIG [621 KPAG] D
NORMAL TEMPERATURE = 50 TO 180°F [10 TO 82.2°C]
FLOW RATE 13 = USGPM [49.2 LPM]
15 APPROXIMATE SYSTEM COOLANT CAPACITY EXCLUDING FIELD PIPING 35 INSTRUMENT AIR NORMAL FLOW REFERS TO LEAKAGE IN SOLENOIDS
SUPPLIED BY OTHERS IS 600 U.S. GALLONS [2270 LITERS]. (REFER TO (NEGLIGIBLE IN THIS CASE). DESIGN FLOW REFERS TO RE-OCCURRING
INTERFACE TABLE ON THIS DOCUMENT FOR ACTUAL MAXIMUMS.) MAXIMUM TRANSIENT FLOW RATE THROUGH SOLENOIDS (DURATION NOT TO
EXCEED 5 SECONDS PER OCCURRENCE).
16 CONTINUOUS FLOW REQUIRED DURING GAS TURBINE/ GENERATOR 36 INTERFACE CONNECTION DESIGN REQUIREMENTS APPLY TO WATER WASH
OPERATION TO PREVENT AIR ACCUMULATION. SYSTEM OPERATION ONLY.
37 MAXIMUM PRESSURE FOR WW19 AND WW1 ARE BASED ON 150# FLANGE
17 IT IS RECOMMENDED THAT THE PIPING ARRANGMENT DEPICTED BELOW IS RATINGS.
USED FOR INTERCONNECTION OF THE GAS TURBINE EQUIPMENT. OTHER
38 DRAIN FLOWS (TANKS AND/OR FLOOR DRAINS) ARE INTERMITTENT.
PIPING CONFIGURATIONS MAY BE POSSIBLE. OTHERS MUST ADD THROTTLING
VALVES AND FLOW MEASURING ORIFICES TO ACHIEVE THE STATED FLOW 39 MAXIMUM ALLOWABLE PRESSURE DROP BETWEEN WW20 AND WW1 IS 10 PSID
RATES. [68.9 KPAD].
COOLING WATER SUPPLY TO CW12 AND CW94 MLI 0471
THEN TO CW6 AND CW52
THEN TO COOLING WATER RETURN 40 PRESSURE DROP IN INTERCONNECT PIPING MUST NOT EXCEED 4 PSID [27.6
C KPAD]. C
18 DURING SYSTEM BALANCING, THE LUBE OIL TEMPERATURE CONTROL VALVE, 41 DESIGN PRESSURE AND TEMPERATURE VALUES ARE NOT CONCURRENT
VA32-1, SHALL BE FORCED TO FULL OPEN. NORMAL CONTROL SHALL BE OPERATING VALUES. DESIGN PRESSURE WILL OCCUR WHEN THE
RETURNED AFTER COMPLETION OF SYSTEM BALANCING. TEMPERATURE IS 647°F [342°C]. DESIGN TEMPERATURE WILL OCCUR WHEN
THE PRESSURE IS 186 PSIG [1280 KPAG].
19 INTERCONNECT PIPING PRESSURE DROP MUST BE LESS THAN OR EQUAL TO 42 EVAPORATIVE COOLER SUPPLY FLOWS REPRESENT A MAXIMUM
10 PSID [68.9 KPAD). TEMPERATURE OF 120°F [48.9°C], 10% RH DAY (90% NOMINAL EFFICIENCY) AND
TWO CYCLES OF CONCENTRAION (BLOW DOWN RATE = EVAPORATIVE RATE).
PIPING BY OTHERS MUST BE SIZED TO OTHERS MAXIMUM EVAPORATIVE
MLI 0422 COOLER FLOWS.
20 NATURAL GAS LHV: 940.1 BTU/SCFT [35.03 MJ/SCM] , 21162 BTU/LB [49.22 MJ/KG]. 43 SUPPLIED LINES BY OTHERS MUST NOT BE REDUCED AND MUST ALLOW
21 OTHERS MUST PROVIDE A PRESSURE RELIEVING DEVICE IN THE FUEL GAS UNRESTRICED FLOW FOR THIS GRAVITY DRAIN. THE LOOP (TRAP) SEAL MUST
SUPPLY PIPING UPSTREAM OF FG1 IN ACCORDANCE WITH ASME B31.3 AND BE DESIGNED FOR A MINIMUM BACK PRESSURE OF 12 INCHES [305 MM] OF
CONSTANT WITH A DESIGN PRESSURE OF 550 PSIG [3790 KPAG]. WATER (MINIMUM 12 INCH [305 MM] TRAP)
22 FG2, FG3, AND FG439 ARE A POTENTIAL SOURCE OF FLAMMABLE 44 IE7 MAXIMUM FLOW BASED ON INSTANT OF EVAPORATIVE COOLER
ATMOSPHERE. THE EXTENT OF THE HAZARDOUS AREA, OTHER INFORMATION, SHUTDOWN WITH MEDIA DRAINING AND MAKEUP WATER VALVE (IE5) LOCKED
AND RECOMMENDATIONS TO ASSIST OTHERS ARE GIVEN IN MLI 0331. OPEN AT MAXIMUM SUPPLY PRESSURE.
B 23 PRESSURE DROP FROM FG20 TO FG21 IS 5 PSID [34.5 KPAD] MAXIMUM. 45 MAXIMUM DEWPOINT = -40°F [-40°C]
46 MAKEUP WATER AND THE RESULTING SUMP MUST BE IN COMPLIANCE WITH
B
24 REFER TO MLI 0331, HAZARDOUS AREA MAP AND NOTES FOR INFORMATION ON
HAZARDOUS AREAS AND RATINGS OF GE SUPPLIED EQUIPMENT. IT IS THE THE LATEST REVISION OF GEK 107158 WITH A MINIMUM OF TWO CYCLES OF
RESPONSIBILITY OF OTHERS TO CARRY OUT ANY NECESSARY FURTHER CONCENTRATION. MAKEUP WATER THAT REQUIRES LESS THAN TWO CYCLES
POWER PLANT HAZARDOUS AREA CLASSIFICATION STUDIES AND TO DESIGN OF CONCENTRATION TO MEET THE REQUIREMENTS OF GEK 107158 IS
AND INSTALL THE PIPING AND EQUIPMENT IN ACCORDANCE WITH APPLICABLE UNACCEPTABLE.
SAFETY CODES AND STANDARDS. GUIDANCE AND INFORMATION IS GIVEN IN MLI 0474
MLI 0331 TO ASSIST OTHERS IN THIS TASK.
47 INSTRUMENT AIR, SUPPLIED BY OTHERS, MUST BE IN ACCORDANCE WITH
PLANT INSTRUMENT AIR SYSTEM REQUIREMENTS INCLUDED IN MLI 0438. AIR
SUPPLY REQUIRED TO BE SUPPLIED PRIOR TO STARTUP OF TURBINE. DESIGN
FLOW PER CONNECTION IS 0.62 CFH [0.017 M^3/H]; MINIMUM PRESSURE IS 90 1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671
PSIG [621 KPAG]. IT. NOMENCLATURE IDENT
48 MAINTENANCE OF INSTRUMENT AIR AT STATED FLOW/PRESSURE CRITICAL LIST OF COMPLEMENTARY DOCUMENTS
FOR TURBINE OPERATION; THESE CONNECTIONS PROVIDE MOTIVE AIR FOR GE CLASS II (INTERNAL NON-CRITICAL)
TURBINE SAFETY CRITICAL SYSTEM THAT MAY RESULT IN TRIP IF AIR IS NOT UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY

PROVIDED. DIMENSIONS ARE IN INCHES

DRAWN
JURADO, ARTURO 12-11-05
g GE Energy GAS TURBINE
TOLERANCES ON CHECKED

A 49 INSTRUMENT AIR REQUIREMENTS ARE INCLUDED IN MLI 0438. INSTRUMENT AIR

MINIMUM PRESSURE MUST BE 90 PSIG [621 KPAG].
© COPYRIGHT 2012 -2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES.
ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE ENERGY GAS
2 PL DECIMALS ±
3 PL DECIMALS ±
ANGLES ±
ENGRG
SEE PLM
LANPHER, NATHAN
12-11-05
12-11-05 Connection & Line List, Customer A
Interface
ISSUED
TURBINE PROPRIETARY TECHNICAL INFORMATION THAT BELONGS TO THE GENERAL FRACTIONS ±
SEE PLM 12-11-05
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR THEIR AFFILIATES, WHICH HAS QUALITY
BEEN PROVIDED SOLELY FOR THE EXPRESS REASON OF RESTRICTED PRIVATE USE.
ALL PERSONS, FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL FIRST MADE FOR: ML-9K1WFA163-1 4063
THIRD ANGLE PROJECTION
BE DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED TO MAKE SIZE CAGE CODE DWG NO
NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER FOR ANY, OR ALL
E 145E4535

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SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY THE GENERAL
SIM TO:

TO
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR ITS AFFILIATES.
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B 1

NORMAL NORMAL NORMAL MINIMUM MINIMUM MINIMUM MAXIMUM MAXIMUM MAXIMUM DESIGN DESIGN DESIGN
CONNECTION SHEET & INTERFACE
MLI FLUID TYPE CONNECTION DESCRIPTION PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW NOTES
NAME ZONE TYPE
PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM]

LO1 0416 SH 2 B8 OIL GEE-OTHERS OIL TANK FILL / RETURN FROM LUBE OIL CONDITIONER 0 [0] 180 [82] 10 [38] --- --- --- --- --- --- 150 [1030] 225 [107] 200 [757] ---

LO2 0416 SH 2 A1 OIL GEE-OTHERS LUBE OIL TANK DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 18 [68.1] ---
H LO13A 0416 SH 2 D1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---
H
LO13B 0416 SH 2 C1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---

LO13C 0416 SH 2 C1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---

LO13D 0416 SH 2 C1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---

LO13E 0416 SH 2 B1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---

LO13F 0416 SH 2 B1 OIL / WATER GEE-OTHERS ACCESSORY COMPARTMENT FLOOR DRAINS 0 [0] 130 [54] 0 [0] --- --- --- --- --- --- 2 [13.8] 225 [107] 3 [11.4] ---

200 TO 300 SCFM

AIR / OIL 500 SCFM
LO19 0416 SH 2 H4 GEE-OTHERS VENT FROM LUBE OIL DEMISTER 0 [0] 180 [82] [5.7 TO 8.5 M^3/ --- --- --- --- --- --- 2 [13.8] 225 [107] SEE NOTE 4
VAPOR [14 M^3/MIN]
MIN]

LO21 0416 SH 2 C8 OIL GEE-OTHERS LUBE OIL TO LUBE OIL CONDITIONER 0 [0] 180 [82] 10 [38] --- --- --- --- --- --- 2 [13.8] 225 [107] 20 [76] ---
G G
LO125 0416 SH 3 D8 OIL GEE-OTHERS GENERATOR SEAL OIL SUPPLY - AT GENERATOR 100 [689] 130 [54] 18 [68.1] --- --- --- --- --- --- 150 [1030] 175 [79] 157 [594] ---

0.24 PPS [0.11 KG/ 0.24 PPS [0.11 KG/

CA5 0417 SH 2 C6 AIR GEE-OTHERS AIR SUPPLY FOR SELF-CLEANING FILTERS 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 7
S] S]
0 TO 32.7 PPS 32.7 PPS [14.8KG/
CA16 0417 SH 2 C5 AIR GEE-OTHERS INLET AIR HEATING 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 7
[0 TO 14.8 KG/S] S]
SEE NOTES
CA20 0417 SH 2 C5 WATER GEE-OTHERS LOW POINT DRAIN, INLET AIR HEATING PIPING 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 252 [1740] 814 [434] 5 [19]
6&7
SEE NOTES
CA52A 0417 SH 2 E8 WATER GEE-OTHERS COMP ST9 LOW POINT WATER WASH DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 71 [490] 553 [290] 5 [19]
6&8
SEE NOTES
CA52B 0417 SH 2 D8 WATER GEE-OTHERS COMP ST9 LOW POINT WATER WASH DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 71 [490] 553 [290] 5 [19]
6&8
SEE NOTES
CA53A 0417 SH 2 E7 WATER GEE-OTHERS COMP ST13 LOW POINT WATER WASH DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 131 [903] 724 [385] 5 [19]
6&9

F CA53B 0417 SH 2 D7 WATER GEE-OTHERS COMP ST13 LOW POINT WATER WASH DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 131 [903] 724 [385] 5 [19]
SEE NOTES
6&9
F
SEE NOTES
CA54 0417 SH 2 F5 WATER GEE-OTHERS LOW POINT WATER WASH DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 252 [1740] 814 [434] 5 [19]
6&7
COMPRESSOR BLEED EXTRACTION VALVE ACTUATION 0.0004 PPS 0.01 PPS
CA60A 0417 SH 2 G1 AIR GEE-OTHERS 90 [621] AMBIENT --- --- --- --- --- --- 110 [758] 120 [48.9] SEE NOTE 5
AIR [0.0002 KG/S] [0.005 KG/S]
COMPRESSOR BLEED EXTRACTION VALVE ACTUATION 0.0004 PPS 0.01 PPS
CA60B 0417 SH 2 F2 AIR GEE-OTHERS 90 [621] AMBIENT --- --- --- --- --- --- 110 [758] 120 [48.9] SEE NOTE 5
AIR [0.0002 KG/S] [0.005 KG/S]
0.0004 PPS 0.01 PPS
CA64 0417 SH 4 G1 AIR GEE-OTHERS HEAT RATE CONTROL VALVE ACTUATION AIR 90 [621] AMBIENT --- --- --- --- --- --- 110 [758] 120 [48.9] SEE NOTE 5
0.0002 KG/S] [0.005 KG/S]
0.0004 PPS 0.01 PPS
CC3 0417 SH 4 H7 AIR GEE-OTHERS INSTRUMENT AIR TO CTM FLOW CONTROL VALVE 90 [621] AMBIENT --- --- --- --- --- --- 110 [758] 120 [48.9] SEE NOTE 5
0.0002 KG/S] [0.005 KG/S]

0.24 PPS [0.11 KG/ 0.24 PPS [0.11 KG/

AP1 0419 SH 1 E7 AIR GEE-OTHERS COMPRESSED AIR INLET 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 10
S] S]
0.20 PPS 0.20 PPS [0.09 KG/
AP2 0419 SH 1 E2 AIR GEE-OTHERS COMPRESSED AIR OUTLET 100 [689] 145 [63] --- --- --- --- --- --- 104 [717] 145 [63] ---
[0.09 KG/S] S]
E E
AP3 0419 SH 1 D2 WATER GEE-OTHERS COALESCER PRE-FILTER DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 2 [13.8] 131 [55] 0.5 [1.9] ---

AP4 0419 SH 1 D2 WATER GEE-OTHERS WATER SEPARATOR DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 2 [13.8] 131 [55] 1.0 [3.8] ---

CW6 0420 SH 2 C7 COOLANT GEE-OTHERS COOLING WATER TO LUBE OIL HEAT EXCHANGERS --- --- --- 65 [448] 57.2 [14] 1000 [3790] 125 [862] 120 [49.1] 1000 [3790] 150 [1030] 200 [93] 1000 [3790] ---

CW7 0420 SH 2 C6 COOLANT GEE-OTHERS COOLING WATER FROM LUBE OIL HEAT EXCHANGERS --- --- --- 65 [448] 57.2 [14] 1000 [3790] 125 [862] 138 [58.9] 1000 [3790] 150 [1030] 200 [93] 1000 [3790] ---

CW12A 0420 SH 3 F8 COOLANT GEE-OTHERS COOLING WATER TO GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 114.8 [46] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW12B 0420 SH 3 F7 COOLANT GEE-OTHERS COOLING WATER TO GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 114.8 [46] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW12C 0420 SH 3 F6 COOLANT GEE-OTHERS COOLING WATER TO GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 114.8 [46] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

D CW12D 0420 SH 3 F6 COOLANT GEE-OTHERS COOLING WATER TO GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 114.8 [46] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---
D
CW13A 0420 SH 3 G8 COOLANT GEE-OTHERS COOLING WATER FROM GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 120 [49.0] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW13B 0420 SH 2 G7 COOLANT GEE-OTHERS COOLING WATER FROM GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 120 [49.0] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW13C 0420 SH 2 G6 COOLANT GEE-OTHERS COOLING WATER FROM GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 120 [49.0] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW13D 0420 SH 2 G6 COOLANT GEE-OTHERS COOLING WATER FROM GENERATOR COOLERS --- --- --- 65 [448] 57.2 [14] 675 [2560] 125 [862] 120 [49.0] 675 [2560] 150 [1030] 200 [93] 675 [2560] ---

CW14A 0420 SH 3 G8 COOLANT GEE-OTHERS GENERATOR COOLER VENTS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW14B 0420 SH 2 G7 COOLANT GEE-OTHERS GENERATOR COOLER VENTS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW14C 0420 SH 2 G7 COOLANT GEE-OTHERS GENERATOR COOLER VENTS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW14D 0420 SH 2 G6 COOLANT GEE-OTHERS GENERATOR COOLER VENTS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---
C C
CW15A 0420 SH 3 F8 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW15B 0420 SH 3 F7 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW15C 0420 SH 3 F6 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW15D 0420 SH 3 F6 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW16A 0420 SH 3 F8 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW16B 0420 SH 3 F7 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW16C 0420 SH 3 F6 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---

CW16D 0420 SH 3 F6 COOLANT GEE-OTHERS GENERATOR COOLER DRAINS --- --- --- 0 [0] 57.2 [14] 0 [0] 125 [862] 120 [49.0] 5 [19] 150 [1030] 200 [93] 5 [19] ---
B B
CW52 0420 SH 2 B8 COOLANT GEE-OTHERS COOLING WATER TO TURBINE BASE --- --- --- 65 [448] 57.2 [14] 6 [23] 125 [862] 120 [49.1] 6 [23] 150 [1030] 200 [93] 6 [23] ---

CW53 0420 SH 2 C6 COOLANT GEE-OTHERS COOLING WATER FROM TURBINE BASE --- --- --- 65 [448] 57.2 [14] 6 [23] 125 [862] 131 [54.7] 6 [23] 150 [1030] 200 [93] 6 [23] ---

CW94 0420 SH 3 G2 COOLANT GEE-OTHERS COOLING WATER TO LCI COOLER --- --- --- 65 [448] 57.2 [14] 50 [189] 125 [862] 115 [46.0] 50 [189] 150 [1030] 200 [93] 50 [189] ---

CW95 0420 SH 3 E2 COOLANT GEE-OTHERS COOLING WATER FROM LCI COOLER --- --- --- 65 [448] 57.2 [14] 50 [189] 125 [862] 129 [53.8] 50 [189] 150 [1030] 200 [93] 50 [189] ---

SH 2 C5 0.5 PPS 31 PPS 31 PPS SEE NOTES 25

FG1 0422 GAS GE-OTHERS FUEL GAS INLET --- --- --- 410 [2830] SEE NOTE 24 500 [3450] 350 [177] 550 [3790] 390 [199]
SH 3 F8 [0.23 KG/S] [14.1 KG/S] [14.1 KG/S] & 26
SH 2 G5 0.7 PPS 0.7 PPS SEE NOTES 22
FG2 0422 GAS GE-OTHERS FUEL GAS STRAINER VENT --- --- --- 0 [0] AMBIENT 0 [0] 500 [3450] 120 [48.9] 550 [3790] 390 [199]
SH 3 F8 [0.32 KG/S] [0.32 KG/S] & 24
SH 2 G5 1 PPS 1 PPS SEE NOTES 22
FG3 0422 GAS/AIR GE-OTHERS FUEL GAS VENT --- --- --- 0 [0] AMBIENT 0 [0] 150 [1030] 814 [434] 150 [1030] 814 [434]
SH 3 H4 [0.45 KG/S] [0.45 KG/S] & 24
0.5 PPS 31 PPS 31 PPS
A FG20 0422 SH 2 C8 GAS GE-OTHERS FUEL GAS FLOW METER INLET --- --- --- 449 [3100] AMBIENT
[0.23 KG/S]
500 [3450] 350 [177]
[14.1 KG/S]
550 [3790] 390 [199]
[14.1 KG/S]
--- A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy
E 145E4535

DISTR
DRAWN
JURADO, ARTURO

TO
ISSUED
SEE PLM
SCALE SHEET
2 of 4

8 7 6 5 4 3 2 1
GE Proprietary Information - Class II (Internal) US EAR - NLR
DWG Number 145E4535 Rev B Released 8/8/2013 Page 3 of 4

8 7 6 5 4 3 2 SIZE

E
DWG. NO.

145E4535
SH.

3
REV.

B 1

NORMAL NORMAL NORMAL MINIMUM MINIMUM MINIMUM MAXIMUM MAXIMUM MAXIMUM DESIGN DESIGN DESIGN
CONNECTION SHEET & INTERFACE
MLI FLUID TYPE CONNECTION DESCRIPTION PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW NOTES
NAME ZONE TYPE
PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM]
0.5 PPS 31 PPS 31 PPS
FG21 0422 SH 2 C7 GAS GE-OTHERS FUEL GAS FLOW METER OUTLET --- --- --- 444 [3060] AMBIENT 500 [3450] 350 [177] 550 [3790] 390 [199] SEE NOTE 28
[0.23 KG/S] [14.1 KG/S] [14.1 KG/S]
0.5 PPS 31 PPS 31 PPS
FG425 0422 SH 2 C7 GAS GE-OTHERS SAFETY SHUTOFF STOP VALVE INLET --- --- --- 414 [2850] AMBIENT 500 [3450] 350 [177] 550 [3790] 390 [199] ---
[0.23 KG/S] [14.1 KG/S] [14.1 KG/S]
H FG426 0422 SH 2 C6 GAS GE-OTHERS SAFETY SHUTOFF STOP VALVE OUTLET --- --- --- 411 [2830] AMBIENT
0.5 PPS
500 [3450] 350 [177]
31 PPS
550 [3790] 390 [199]
31 PPS
---
H
[0.23 KG/S] [14.1 KG/S] [14.1 KG/S]
SAFETY SHUTOFF STOP UPPER VALVE PACKING LEAK 0.003 PPS 0.003 PPS
FG428A 0422 SH 2 D6 GAS GE-OTHERS --- --- --- 0 [0] AMBIENT 0 [0] 500 [3450] 350 [177] 550 [3790] 390 [199] ---
OFF [0.001 KG/S] [0.001 KG/S]
SAFETY SHUTOFF STOP UPPER VALVE PACKING LEAK 0.003 PPS 0.003 PPS
FG428B 0422 SH 2 D7 GAS GE-OTHERS --- --- --- 0 [0] AMBIENT 0 [0] 500 [3450] 350 [177] 550 [3790] 390 [199] ---
OFF [0.001 KG/S] [0.001 KG/S]
57 PPS 57 PPS
FG438 0422 SH 2 E6 GAS GE-OTHERS SAFETY SHUTOFF VENT VALVE INLET --- --- --- 411 [2830] AMBIENT 0 [0] 500 [3450] 350 [177] 550 [3790] 390 [199] ---
[25.9 KG/S] [25.9 KG/S]
57 PPS 57 PPS SEE NOTES 22
FG439 0422 SH 2 E6 GAS GE-OTHERS SAFETY SHUTOFF VENT VALVE OUTLET --- --- --- 0 [0] AMBIENT 0 [0] 500 [3450] 350 [177] 550 [3790] 390 [199]
[25.9 KG/S] [25.9 KG/S] & 24
SH 2 G5 0.01 PPS 0.04 PPS
FG7 0422 AIR GE-OTHERS INSTRUMENT AIR SUPPLY 105 [724] AMBIENT --- --- --- --- --- --- 120 [827] 150 [65.6] SEE NOTE 27
SH 3 H2 [0.005 KG/S] [0.02 KG/S]
0.01 PPS 0.04 PPS
FG427 0422 SH 2 D6 AIR GE-OTHERS INSTRUMENT AIR GAS SAFETY SHUT OFF STOP VALVE 105 [724] AMBIENT --- --- --- --- --- --- 120 [827] 150 [65.6] SEE NOTE 27
[0.005 KG/S] [0.02 KG/S]
0.01 PPS 0.04 PPS
FG440 0422 SH 2 E6 AIR GE-OTHERS INSTRUMENT AIR GAS SAFETY SHUT OFF VENT VALVE 105 [724] AMBIENT --- --- --- --- --- --- 120 [827] 150 [65.6] SEE NOTE 27
[0.005 KG/S] [0.02 KG/S]
G G
DUAL PHASE
45.1 TO 51.5 PPS 45.1 TO 51.5 PPS
FLOW LIQUID 220 TO 250 220 TO 250 SEE NOTES 29
NN7 0426 SH 2 B2 GEE-OTHERS FILL CONNECTION 0 [-17.8] [20.0 TO 23.4 KG/ --- --- --- --- --- --- 0 [-17.8] [20.0 TO 23.4 KG/
CO2 AND [1520 TO 1720] [1520 TO 1720] & 30
S] S]
CO2 GAS
0.076 TO 0.089 0.076 TO 0.089
220 TO 250 PPS 220 TO 250 PPS SEE NOTES 29
NN8 0426 SH 2 B2 CO2 GAS GEE-OTHERS VAPOR RETURN CONNECTION 0 [-17.8] --- --- --- --- --- --- 0 [-17.8]
[1520 TO 1720] [0.034 TO 0.040 [1520 TO 1720] [0.034 TO 0.040 & 230
KG/S] KG/S]
DUAL PHASE
FLOW LIQUID 6.1 TO 7.67 PPS 6.1 TO 7.67 PPS
FP25 0426 SH 3 G2 GEE-OTHERS NO.2 BEARING INITIAL DISCHARGE SUPPLY 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND [2.8 TO 3.48 KG/S] [2.8 TO 3.48 KG/S]
CO2 GAS
DUAL PHASE
0.31 TO 0.34 PPS 0.31 TO 0.34 PPS
FLOW LIQUID
FP26 0426 SH 3 G3 GEE-OTHERS NO.2 BEARING EXTENDED DISCHARGE SUPPLY 325 [2240] 0 [-17.8] [0.14 TO 0.15 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.14 TO 0.15 KG/ SEE NOTE 29
CO2 AND
S] S]
CO2 GAS
F DUAL PHASE F
FLOW LIQUID 3.7 TO 4.88 PPS 3.7 TO 4.88 PPS
FP31 0426 SH 3 D4 GEE-OTHERS LUBE OIL COMPARTMENT INITIAL DISCHARGE 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND [1.7 TO 2.21 KG/S] [1.7 TO 2.21 KG/S]
CO2 GAS
DUAL PHASE
0.18 TO 0.19 PPS 0.18 TO 0.19 PPS
FLOW LIQUID
FP32 0426 SH 3 D4 GEE-OTHERS LUBE OIL COMPARTMENT EXTENDED DISCHARGE 325 [2240] 0 [-17.8] [0.080 TO 0.086 --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.080 TO 0.086 SEE NOTE 29
CO2 AND
KG/S] KG/S]
CO2 GAS
DUAL PHASE
FLOW LIQUID 24.1 PPS 24.1 PPS SEE NOTES 29
NN44 0426 SH 2 A2 GEE-OTHERS COMMON RELIEF VALVE VENT 14.7 [101] 60 [15.6] --- --- --- --- --- --- 14.47 [101] 60 [15.6]
CO2 AND [10.9 KG/S] [10.9 KG/S] & 30
CO2 GAS
DUAL PHASE
37.2 TO 43.1 PPS 37.2 TO 43.1 PPS
FLOW LIQUID TURBINE DISCHARGE COMPARTMENT INITIAL
FP60 0426 SH 3 F4 GEE-OTHERS 325 [2240] 0 [-17.8] [16.9 TO 19.5 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [16.9 TO 19.5 KG/ SEE NOTE 29
CO2 AND DISCHARGE SUPPLY
S] S]
CO2 GAS
DUAL PHASE
0.94 TO 1.23 PPS 0.94 TO 1.23 PPS
E FP61 0426 SH 3 F4
FLOW LIQUID
CO2 AND
GEE-OTHERS
TURBINE DISCHARGE COMPARTMENT EXTENDED
DISCHARGE SUPPLY
325 [2240] 0 [-17.8] [0.43 TO 0.56 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.43 TO 0.56 KG/ SEE NOTE 29 E
S] S]
CO2 GAS
DUAL PHASE
FLOW LIQUID 0.083 PPS [0.038 0.083 PPS [0.038
FP91 0426 SH 3 F4 GEE-OTHERS TURBINE COMPARTMENT PNEUMATIC SIREN 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND KG/S] KG/S]
CO2 GAS
DUAL PHASE
FLOW LIQUID 0.083 PPS [0.038 0.083 PPS [0.038
FP93 0426 SH 3 D4 GEE-OTHERS LUBE OIL COMPARTMENT PNEUMATIC SIREN 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND KG/S] KG/S]
CO2 GAS
DUAL PHASE
37.2 TO 43.1 PPS 37.2 TO 43.1 PPS
FLOW LIQUID TURBINE DISCHARGE COMPARTMENT INITIAL
NN1 0426 SH 2 C3 GEE-OTHERS 325 [2240] 0 [-17.8] [16.9 TO 19.5 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [16.9 TO 19.5 KG/ SEE NOTE 29
CO2 AND DISCHARGE SUPPLY
S] S]
CO2 GAS
DUAL PHASE
0.94 TO 1.23 PPS 0.94 TO 1.23 PPS
FLOW LIQUID TURBINE DISCHARGE COMPARTMENT EXTENDED
NN2 0426 SH 2 C3 GEE-OTHERS 325 [2240] 0 [-17.8] [0.43 TO 0.56 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.43 TO 0.56 KG/ SEE NOTE 29
D CO2 AND
CO2 GAS
DISCHARGE SUPPLY
S] S] D
DUAL PHASE
FLOW LIQUID 6.1 TO 7.67 PPS 6.1 TO 7.67 PPS
NN3 0426 SH 2 C2 GEE-OTHERS NO.2 BEARING INITIAL DISCHARGE SUPPLY 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND [2.8 TO 3.48 KG/S] [2.8 TO 3.48 KG/S]
CO2 GAS
DUAL PHASE
0.31 TO 0.34 PPS 0.31 TO 0.34 PPS
FLOW LIQUID
NN4 0426 SH 2 C3 GEE-OTHERS NO.2 BEARING EXTENDED DISCHARGE SUPPLY 325 [2240] 0 [-17.8] [0.14 TO 0.15 KG/ --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.14 TO 0.15 KG/ SEE NOTE 29
CO2 AND
S] S]
CO2 GAS
DUAL PHASE
FLOW LIQUID 3.7 TO 4.88 PPS 3.7 TO 4.88 PPS
NN5 0426 SH 2 C4 GEE-OTHERS LUBE OIL COMPARTMENT INITIAL DISCHARGE 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND [1.7 TO 2.21 KG/S] [1.7 TO 2.21 KG/S]
CO2 GAS
DUAL PHASE
0.18 TO 0.19 PPS 0.18 TO 0.19 PPS
FLOW LIQUID
NN6 0426 SH 2 C4 GEE-OTHERS LUBE OIL COMPARTMENT EXTENDED DISCHARGE 325 [2240] 0 [-17.8] [0.080 TO 0.086 --- --- --- --- --- --- 450 [3100] 0 [-17.8] [0.080 TO 0.086 SEE NOTE 29
CO2 AND
KG/S] KG/S]
CO2 GAS
C DUAL PHASE
C
FLOW LIQUID 0.083 PPS [0.038 0.083 PPS [0.038
NN31 0426 SH 2 C3 GEE-OTHERS TURBINE COMPARTMENT PNEUMATIC SIREN 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND KG/S] KG/S]
CO2 GAS
DUAL PHASE
FLOW LIQUID 0.083 PPS [0.038 0.083 PPS [0.038
NN33 0426 SH 2 C4 GEE-OTHERS LUBE OIL COMPARTMENT PNEUMATIC SIREN 325 [2240] 0 [-17.8] --- --- --- --- --- --- 450 [3100] 0 [-17.8] SEE NOTE 29
CO2 AND KG/S] KG/S]
CO2 GAS

0 TO 32.7 PPS 32.7 PPS [14.8KG/

IH1 0432 SH 1 C5 AIR GEE-GEE INLET HEATING CONTROL VALVE INLET 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 33
[0 TO 14.8 KG/S] S]
0 TO 32.7 PPS 32.7 PPS [14.8KG/
IH2 0432 SH 1 C3 AIR GEE-GEE INLET HEATING CONTROL VALVE OUTLET 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 33
[0 TO 14.8 KG/S] S]
0 TO 32.7 PPS 32.7 PPS [14.8KG/
IH3 0432 SH 1 C7 AIR GEE-GEE INLET HEATING ISOLATION VALVE INLET 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 33
[0 TO 14.8 KG/S] S]
0 TO 32.7 PPS 32.7 PPS [14.8KG/
IH4 0432 SH 1 C6 AIR GEE-GEE INLET HEATING ISOLATION VALVE OUTLET 223 [1540] 754 [401] --- --- --- --- --- --- 252 [1740] 814 [434] SEE NOTE 33
B [0 TO 14.8 KG/S] S] B
.006 PPS [.003 KG/
INSTRUMENT AIR SUPPLY TO INLET HEAT CONTROL .0004 PPS [.0002
IH7 0432 SH 1 E7 AIR GEE-OTHERS 90 [621] AMBIENT --- --- --- --- --- --- 110 [758] 120 [48.9] S] ---
VALVE KG/S]
TRANSIENT

LOAD COMPARTMENT EXHAUST (COMPARTMENT -20 TO 200 6400 ACFM

HV8 0436 SH 3 D8 AIR GEE-OTHERS --- --- --- 0 [0] AMBIENT --- 0 [0] 163 [72.8] --- 223 [1540] ---
INTERFACE) [-29 TO 93] [181 M^3/MIN]
ACCESSORY MODULE (LUBE OIL REGION) EXHAUST -20 TO 160 7400 ACFM
HV9 0436 SH 3 F6 AIR GEE-OTHERS --- --- --- 0 [0] AMBIENT --- 0 [0] 133 [56.1] --- 105 [724] ---
(COMPARTMENT INTERFACE) [-29 TO 71] [210 M^3/MIN]

IE4 0442 SH 2 C5 WASH WATER GEE-OTHERS DRAIN FROM INLET PLENUM 0 [0] 180 [82.2] 15 [57] --- --- --- --- --- --- 5 [34.5] 212 [100] 15 [57] ---

SEE NOTES 34,

WW1 0442 SH 2 C7 WASH WATER GEE-OTHERS WATER WASH TO SPRAY MANIFOLDS SEE NOTE 34 SEE NOTE 34 SEE NOTE 34 --- --- --- --- --- --- 110 [758] 212 [100] 58.5 [221]
37 & 39

WW10 0442 SH 2 D3 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM TURBINE SHELL AFT 2 [13.8] 212 [100] 5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] ---

A A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy
E 145E4535

DISTR
DRAWN
JURADO, ARTURO

TO
ISSUED
SEE PLM
SCALE SHEET
3 of 4

8 7 6 5 4 3 2 1
GE Proprietary Information - Class II (Internal) US EAR - NLR
DWG Number 145E4535 Rev B Released 8/8/2013 Page 4 of 4

8 7 6 5 4 3 2 SIZE

E
DWG. NO.

145E4535
SH.

4
REV.

B 1

NORMAL NORMAL NORMAL MINIMUM MINIMUM MINIMUM MAXIMUM MAXIMUM MAXIMUM DESIGN DESIGN DESIGN
CONNECTION SHEET & INTERFACE
MLI FLUID TYPE CONNECTION DESCRIPTION PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW PRESSURE TEMPERATURE FLOW NOTES
NAME ZONE TYPE
PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM] PSIG [KPAG] °F [°C] USGPM [LPM]
0.003 PPS [0.001
WW111 0442 SH 2 D7 AIR GEE-OTHERS INSTRUMENT AIR SUPPLY TO VA16-1 100 [689] 175 [79] 0 [0] --- --- --- --- --- --- 120 [827] 175 [79] SEE NOTE 35
KG/S]
0.001 PPS [0.0004
WW112 0442 SH 2 C6 AIR GEE-OTHERS INSTRUMENT AIR SUPPLY TO VA16-3 100 [689] 175 [79] 0 [0] --- --- --- --- --- --- 120 [827] 175 [79] SEE NOTE 35
KG/S]
H WW12 0442 SH 2 E7 WASH WATER GEE-OTHERS OFF-LINE FEED WATER DRAIN 4 [27.6]
50 TO 180
5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] SEE NOTE 38
H
[10 TO 82.2]
50 TO 180
WW13 0442 SH 2 D6 WASH WATER GEE-OTHERS ON-LINE FEED WATER DRAIN 4 [27.6] 5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] SEE NOTE 38
[10 TO 82.2]

WW15 0442 SH 2 D3 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM EXHAUST DIFFUSER FWD 4 [27.6] 212 [100] 5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] ---

WW16 0442 SH 2 D3 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM EXHAUST DIFFUSER AFT 4 [27.6] 212 [100] 5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] ---

WW24 0442 SH 2 D2 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM EXHAUST DUCT 2 [13.8] 212 [100] 21.5 [81] --- --- --- --- --- --- 5 [34.5] 212 [100] 21.5 [81] ---

WW30 0442 SH 2 D4 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM TURBINE SHELL MANWAY 2 [13.8] 212 [100] 28 [106] --- --- --- --- --- --- 5 [34.5] 212 [100] 28 [106] ---

WW33 0442 SH 2 C5 WASH WATER GEE-OTHERS WASH WATER DRAIN FROM COMBUSTION SYSTEM 2 [13.8] 212 [100] 32 [121] --- --- --- --- --- --- 5 [34.5] 212 [100] 32 [121] ---

WW19 0442 SH 1 E6 WATER GEE-OTHERS WATER TANK INLET 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 120 [827] 122 [50] 100 [379] SEE NOTE 37

G WW20 0442 SH 1 C2 WASH WATER GEE-OTHERS WATER MIX OUTLET SEE NOTE 34 SEE NOTE 34 SEE NOTE 34 --- --- --- --- --- --- 110 [758] 212 [100] 58.5 [221]
SEE NOTES 34 G
& 39

WW21 0442 SH 1 G5 DETERGENT GEE-OTHERS DETERGENT TANK INLET 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 60 [414] 122 [50] 50 [189] ---

WW22 0442 SH 1 F6 DETERGENT GEE-OTHERS DETERGENT TANK DRAIN 0 [0] 65 [18.3] 0 [0] --- --- --- --- --- --- 3 [20.7] 122 [50] 10 [37.9] SEE NOTE 38

50 TO 180
WW23 0442 SH 1 B5 WATER GEE-OTHERS WATER TANK DRAIN 0 [0] 0 [0] --- --- --- --- --- --- 3 [20.7] 212 [100] 25 [94.6] SEE NOTE 38
[10 TO 82.2]

WW29 0442 SH 1 B6 WATER GEE-OTHERS FLOOR DRAIN 0 [0] 65 [18.3] 0 [0] --- --- --- --- --- --- 3 [20.7] 122 [50] 25 [94.6] SEE NOTE 38

0.003 PPS [0.001

WW121 0442 SH 2 D7 AIR GEE-OTHERS INSTRUMENT AIR SUPPLY TO VA16-4 100 [689] 175 [79] 0 [0] --- --- --- --- --- --- 120 [827] 175 [79] SEE NOTE 35
KG/S]
B1
50 TO 180 [10 TO
WW122 0442 SH 2 D8 WASH WATER GEE-OTHERS OFF-LINE FEED WATER DRAIN 4 [27.6] 5.5 [21] --- --- --- --- --- --- 5 [34.5] 212 [100] 5.5 [21] SEE NOTE 38
82.2]

0.20 PPS 0.20 PPS SEE NOTES 40

IE2 0471 SH 1 C6 AIR GEE-OTHERS COMPRESSED AIR INLET 100 [689] 145 [63] --- --- --- --- --- --- 104 [717] 145 [63]
[0.09 KG/S] [0.09 KG/S] & 43
F IE20 0471 SH 2 F6 AIR GEE-OTHERS AIR INLET FOR INLET HEATING 223 [1540] 754 [401]
0 TO 32.7 PPS
--- --- --- --- --- --- 252 [1740] 814 [434]
32.7 PPS SEE NOTES 40 F
[0 TO 14.8 KG/S] [14.8 KG/S] & 41
DUST / 6.5 PPS
IE116 0471 SH 1 B5 GEE-OTHERS SCREW AUGER DRAIN 0 [0] AMBIENT 0 [0] --- --- --- --- --- --- 25 [172] 122 [50] ---
PARTICULATE [2.95 KG/S]

SEE NOTES 47
HG17 0474 SH 1 H5 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG24 0474 SH 1 G5 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG31 0474 SH 1 H2 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG38 0474 SH 1 G2 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG45 0474 SH 1 C2 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG52 0474 SH 1 D2 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
E & 48 E
SEE NOTES 47
HG78 0474 SH 1 D7 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG79 0474 SH 1 C7 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48
SEE NOTES 47
HG80 0474 SH 1 D5 AIR GEE-OTHERS AIR SUPPLY FOR COMB GAS ASPIRATOR 105 [724] AMBIENT 0.62 [2.35] --- --- --- --- --- --- 120 [827] 150 [66] 0.75 [2.83]
& 48

0.04 PPS 1.0 PPS

PG1 0477 SH 2 H2 AIR / GAS GEE-OTHERS GAS PURGE VALVE VENT (D5) 0 [0] AMBIENT --- --- --- --- --- --- 52 [359] 814 [434] SEE NOTE 50
[0.02 KG/S] [0.45 KG/S]
0.04 PPS [0.02 KG/ 1.0 PPS [0.45 KG/
PG13 0477 SH 2 C2 AIR / GAS GEE-OTHERS GAS PURGE VALVE VENT (PM2) 0 [0] AMBIENT --- --- --- --- --- --- 52 [359] 814 [434] SEE NOTE 50
S] S]

0.51 PPD 5.09 PPD 33.9 PPD

FG257 4035 SH 1 D8 GAS GEE-OTHERS SAMPLE PROBE INLET (ACTIVE) --- --- --- 35 [241] -20 [-29] 500 [3450] 365 [185] 550 [3790] 390 [190] ---
[0.23 KG/D] [2.31 KG/D] [15.4 KG/D]
0.51 PPD 5.09 PPD 33.9 PPD
FG258 4035 SH 1 C8 GAS GEE-OTHERS SAMPLE PROBE INLET (SPARE) --- --- --- 35 [241] -20 [-29] 500 [3450] 365 [185] 550 [3790] 390 [190] ---
D [0.23 KG/D]
0.51 PPD
[2.31 KG/D]
5.09 PPD
[15.4 KG/D]
33.9 PPD
D
FG259 4035 SH 1 D5 GAS GEE-OTHERS SAMPLE STREAM TO GAS CHROMATOGRAPH (ACTIVE) --- --- --- 20 [138] 90 [32] 25 [172] 365 [185] 100 [689] 390 [190] ---
[0.23 KG/D] [2.31 KG/D] [15.4 KG/D]
0.51 PPD 5.09 PPD 33.9 PPD
FG260 4035 SH 1 C5 GAS GEE-OTHERS SAMPLE STREAM TO GAS CHROMATOGRAPH (SPARE) --- --- --- 20 [138] 90 [32] 25 [172] 365 [185] 100 [689] 390 [190] ---
[0.23 KG/D] [2.31 KG/D] [15.4 KG/D]
2.30 PPD 5.09 PPD 33.9 PPD
FG261 4035 SH 1 B5 GAS GEE-OTHERS STREAM BYPASS VENT --- --- --- 0 [0] 90 [32] 200 [1380] 130 [54] 250 [1720] 130 [54] SEE NOTE 51
[1.04 KG/D] [2.31 KG/D] [15.4 KG/D]
0.13 PPD 0.28 PPD 565 PPD
FG262 4035 SH 1 G4 GAS GEE-OTHERS SAMPLE VENT --- --- --- 0 [0] 90 [32] 200 [1380] 130 [54] 250 [1720] 130 [54] SEE NOTE 51
[0.06 KG/D] [0.13 KG/D] [256 KG/D]
0.51 PPD 5.09 PPD 33.9 PPD
FG264 4035 SH 1 D6 GAS GEE-OTHERS SAMPLE PROBE OUTLET (ACTIVE) --- --- --- 20 [138] 90 [32] 25 [172] 365 [185] 100 [689] 390 [190] ---
[0.23 KG/D] [2.31 KG/D] [15.4 KG/D]
0.51 PPD 5.09 PPD 33.9 PPD
FG265 4035 SH 1 C6 GAS GEE-OTHERS SAMPLE PROBE OUTLET (SPARE) --- --- --- 20 [138] 90 [32] 25 [172] 365 [185] 100 [689] 390 [190] ---
[0.23 KG/D] [2.31 KG/D] [15.4 KG/D]

C C

B B

A A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy
E 145E4535

DISTR
DRAWN
JURADO, ARTURO

TO
ISSUED
SEE PLM
SCALE SHEET
4 of 4

8 7 6 5 4 3 2 1
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GE Proprietary Information - Class II (Internal) US EAR - NLR

Tab 4
g
GEK 116642
April 2010

GE Energy

Turbine Control Devices

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 116642 Turbine Control Devices

TABLE OF CONTENTS

I. INTRODUCTION.......................................................................................................................... 3

II. OVERVIEW ................................................................................................................................... 3

III. DEVICE NOMENCLATURE ...................................................................................................... 4

IV. FUNCTIONAL DESCRIPTION .................................................................................................. 5

V. CALIBRATION AND MAINTENANCE .................................................................................... 9

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Turbine Control Devices GEK 116642

I. INTRODUCTION

The turbine control device schematic (MLI 0415) shows devices that provide feedback on the conditions
of the gas turbine. These inputs are sent to controls software and used in the control or monitoring of the
gas turbine. The conditions of the gas turbine covered by the devices on the schematic are as follows:

• Presence of Flame in Combustors

• Inlet Bell-Mouth Temperatures (°F, °C)

• Exhaust Temperatures (°F, °C)

• Bearing Temperatures (°F, °C)

• Wheelspace Temperatures (°F, °C)

• Vibration at Bearings (in/sec)

• Turbine Rotational Speed (rpm)

• Turbine Ignition System

II. OVERVIEW

The areas mentioned above are covered by categories of devices. Each device will provide the data needed
to analyze the given area of the turbine. This data will then be given to controls to perform any monitoring,
diagnostics, alarm, or trip function. Device categories are as follows:

• Combustion Flame Detectors

• Magnetic Speed Pickups

• Combustion Ignition Exciter / Spark Plugs

• Compressor Discharge Thermocouples

• Turbine Case Temperature Management Thermocouples

• Exhaust Thermocouples

• Wheelspace Thermocouples

• Inner Barrel Thermocouples

• Inlet Plenum Thermocouples

• Journal Bearing Thermocouples

• Thrust Bearing Thermocouples

• Casing Movement, Seismic Sensor

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 116642 Turbine Control Devices

• Bearing Displacement, Vibration Probe

III. DEVICE NOMENCLATURE

XX designates specific number related to location and/or quantity. Device XX number may change per
frame size. See 0415 drawing on the new unit and applicable mod BOMs for project specific devices.

1. Combustion Flame Detectors:

28FD-XX

2. Magnetic Speed Pickups

77HT-XX

77NH-XX

3. Combustion Ignition Exciter / Spark Plugs

30SG-1 (relay)

95SG-XX (exciter)

95SP-XX (sparkplug)

4. Compressor Discharge Thermocouples

CT-DA-XX

5. Turbine Case Temperature Management Thermocouples

TT-TC-XX

6. Exhaust Thermocouples

TT-XD-XX

7. Wheelspace Thermocouples

TT-WS1AO-XX (first stage aft outer)

TT-WS2AO-XX (second stage aft outer)

TT-WS3AO-XX (third stage aft outer)

TT-WS1F1-XX (first stage forward inner)

TT-WS2FO-XX (second stage forward outer)

TT-WS3FO-XX (third stage forward outer)

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Turbine Control Devices GEK 116642

8. Inner Barrel Thermocouples

TT-IB-XX

9. Inlet Plenum Thermocouples

CT-IF-XX

10. Journal Bearing Thermocouples

BT-J1-XXA,XXB

BT-J2-XXA,XXB

BT-J3-XXA,XXB

11. Thrust Bearing Thermocouples

BT-TA1-XXA,XXB (multiple)

BT-TI1-XXA,XXB (multiple)

12. Casing Movement, Seismic Sensor

39V-XX

13. Bearing Displacement, Vibration Probe

39VS-XX

96VC-XX

77RP-XX

IV. FUNCTIONAL DESCRIPTION

Below provides a generic description of the devices and their functionality.

1. Combustion Flame Detectors

• Purpose: Flame Detectors are used to detect the presence of flame in the combustion cans.

• Controls Impact: Signal used by Turbine Control Panel (TCP), for turbine control.

• Additional Information: Typical combustion can location of Flame detectors are: 7E –2,3,7,8;
7F – 11,12,13,14; 9F – 15,16,17,18. In these specific cans only one flame detector is used. In
DLN applications on 7E, secondary and primary flame detectors are used resulting in two flame
detectors per combustion can.

• Typically provided by: MLI 1121

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

GEK 116642 Turbine Control Devices

2. Magnetic Speed Pickups

• Purpose: Magnetic speed pickups are used to detect the speed of the turbine by monitoring the
speed of a multi-toothed wheel.

• Controls Impact: Speed signal used by TCP, for overspeed and trip functions.

• Additional Information: Two sets of three sensors are used for triple modular redundancy func-
tionality. One set is used for overspeed and the other for trip.

• Typically provided by: MLI 0546

3. Combustion Ignition Exciter / Spark Plugs

• Purpose: Ignition exciter and sparkplugs are used when firing the turbine.

• Controls Impact: Signal used by TCP, for turbine control.

• Additional Information: Two sparkplugs placed in the combustion cans are used for firing. This
initial spark will provide the flame needed to all cans via cross-fire tubes.

• Typically provided by: MLI 1213 (ignition exciter and leads) and 1214 (sparkplugs)

4. Compressor Discharge Thermocouples

• Purpose: Compressor discharge thermocouples are used to monitor temperature at the point when
air exits the last stage of the compressor.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: Three TC’s are placed at the compressor discharge location on the bottom
side of the turbine.

• Typically provided by: MLI 0637

• Typically located by: MLI 0219

5. Turbine Case Temperature Management Thermocouples

• Purpose: Turbine Case Temperature Management Thermocouples are used to monitor tempera-
ture in the turbine casing stage one region.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: Multiple TC’s are used in a circular array placed around the turbine
section.

• Typically provided by: MLI 0637

• Typically interface with: MLI 0705 turbine casing

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Turbine Control Devices GEK 116642

6. Exhaust Thermocouples

• Purpose: Exhaust thermocouples are used to monitor temperature in the exhaust area.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: Multiple TC’s are used in a circular array around the exhaust diffuser.

• Typically provided by: MLI 0623

• Typically interface with: MLI 0706 exhaust diffuser

7. Wheelspace Thermocouples

• Purpose: Wheelspace thermocouples are used to monitor temperature in the turbine rotor
wheelspace.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: Overall 12 wheelspace TC’s are used in six locations with each location
having redundant TC’s.

• Typically provided by: MLI 0637

• Typically interface with: Guide tubes that are located in the turbine casing, nozzles, and inner
barrel.

8. Inner Barrel Thermocouples

• Purpose: Inner Barrel thermocouples are used to monitor temperature in the inner barrel of the
exhaust diffuser.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: Three TC’s are placed in the inner barrel, with one at the top inside
position of the inner barrel and two on either side of the inner barrel.

• Typically provided by: MLI 0637

• Typically interface with: MLI 0706.

9. Inlet Plenum Thermocouples

• Purpose: Inlet plenum thermocouples are used to monitor temperature in the inlet plenum.

• Controls Impact: Temperature signal used by TCP, for turbine control.

• Additional Information: The inlet may be arranged in four different ways: up and fwd, right
side, left side, bottom inlet turbine plenum. The most common of these is up and fwd. Each
configuration has three TC’s for temperature measurement.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116642 Turbine Control Devices

• Typically provided by: MLI 0637

10. Journal Bearing Thermocouples

• Purpose: Journal bearing thermocouples are used to monitor temperature in the journal bearing.

• Controls Impact: Temperature signal used by TCP, for turbine monitoring.

• Additional Information: Two TC’s are located in the first, second and third bearings, depending
on frame size.

• Typically provided by: MLI 235A/B/C

11. Thrust Bearing Thermocouples

• Purpose: Thrust bearing thermocouples are used to monitor temperature in the thrust bearing.

• Controls Impact: Temperature signal used by TCP, for turbine monitoring.

• Additional Information: A total of four TC’s, 2 per bearing, are used to measure temperature on
the active and inactive thrust on the first bearing.

• Typically provided by: MLI 235A

12. Casing Movement, Seismic Sensor

• Purpose: Seismic sensors are used to monitor velocity of vertical movement on the casing of the
turbine.

• Controls Impact: When movement is detected signal is used by TCP, for turbine control.

• Additional Information: Redundant sensors are place at the top of every bearing, except for the
number two bearing on 7E. Excessive vibration detected by these sensors creates a turbine trip.

• Typically provided by: MLI 218A/B/C

13. Bearing Displacement, Vibration Probe

• Purpose: Shaft axial & radial position probes and keyphasor are all used in detecting bearing
displacement.

• Controls Impact: When displacement is detected signal is used by TCP, for turbine control.

• Additional Information: Probes are places on the X and Y axis 90 degrees apart.

• Typically provided by: MLI 235A/B/C

8 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Turbine Control Devices GEK 116642

The table below provides device ordering MLI and interfaces MLI. See new unit BOM for specific draw-
ings.

Devices Ordering MLI Typical Interface MLI's

Flame Detectors 1121 1127, 0401
Magnetic Speed Pickups 0546 1159, 0401
Ignition Exciter / Spark Plugs 1213, 1214 1105, 0401
Compressor Discharge Thermocouples 0637 0219, 1118, 0401
Turbine Case Temperature Management 0637 0705, 9019, 1118, 0401
Thermocouples
Exhaust Thermocouples 0623 1625, 0706, 1160, 0401
1402, 0218, 1409, 0706, 1118,
Wheelspace Thermocouples 0637 1160, 0401
Inner Barrel Thermocouples 0637 0706, 1160, 0401
Inlet Plenum Thermocouples 0637 1612, 1159, 0401
0706, 0801, 0805, 1501, 1502,
Journal Bearing Thermocouples 235A, 235B, 235C 1503, 1507, 1154, 1159, 1160, 0401
0706, 0801, 0805, 1501, 1502,
Thrust Bearing Thermocouples 235A, 235B, 235C 1503, 1507, 1154, 1159, 1160, 0401
Casing Movement, Seismic Sensor 218A, 218B, 218C 1159, 1160, 0401
Bearing Displacement, Vibration Probe 235A, 235B, 235C 235A, 235B, 235C

V. CALIBRATION AND MAINTENANCE

For calibration, maintenance and replacement guidelines consult the manufacturer’s operation and mainte-
nance manual or appropriate GE specifications and arrangement drawings.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 9

GEK 116642 Turbine Control Devices

g
GE Energy
General Electric Company
www.gepower.com

10 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Tab 5
 Inlet Filter House Arrangement Without Evaporative Cooler

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Dirt removal maybe with a screw conveyor or extraction fans.

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TS1000 Coalescer Filters- located in weather hoods

Cleaning

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PULSE FILTER CARTRIDGES

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GE Proprietary Information - Class II (Internal) US EAR - NLR
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GE Proprietary Information - Class II (Internal) US EAR - NLR
FOR TRAINING PURPOSES
- SHEETS 3 & 4 HAVE BEEN
DELETED
 
 
AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:
Bassington Lane PULSE FILTER CONTROL SYSTEM 1
MB 07/01/13
Cramlington
SJH 07/01/13
GB00219848
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 1 OF 6
GREENVILLE

Refer to circuit diagram GB-00219246 & P & I Diagram GB00219247.

The Air Intake Filter System will be supplied as 7 vertical modules. Each module will be equipped with 1 x 24
way manifold, 1 x 20 way manifold and 1 x 10 way manifold connected via rigid connections. These 21
manifolds will be connected to the main compressed air pipe located at the bottom of the modules.

Each module contains 4 canister filter element pairs wide x 27 canister filter element pairs high (total 756 for
all 7 modules).

The Air Intake Filter System is equipped with 1 pulse filter compressed air pipe, which is connected to 378
pulse diaphragm valves. Each valve will control a pulse of cleaning air to 2 canister filter element pairs.

The diaphragm valves are controlled by local solenoid valves. The solenoid valves are housed in
enclosures.
Each 24 way manifold will be fitted with 3 x solenoid enclosures. Each enclosure will house 8 x solenoid
valves.
Each 20 way manifold will be fitted with 2 x solenoid enclosures. Each enclosure will house 10 x solenoid
valves.
Each 10 way manifold will be fitted with 1 x solenoid enclosure. Each enclosure will house 10 x solenoid
valves.

The solenoids are energised by a pulse sequence control circuit board located in the Pulse Filter Control
Panel situated on the access side of the lower left hand filter house.

Each pulse output from the circuit boards will operate 6 valves simultaneously.

REV: 1 FIRST ISSUE MB SJH 07/01/13

AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:

Bassington Lane PULSE FILTER CONTROL SYSTEM 1
MB 07/01/13
Cramlington
GB00219848
SJH 07/01/13

  !"#

 
 
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 2 OF 6
GREENVILLE

Preparing the system for pulse cleaning

Prior to operating the filter cleaning system it will be necessary to carry out the following.

- Ensure all Control Panel MCB0$!4
- Switch on the filter control panel isolator Q1.
- The 110V control supply indicator H1 will illuminate.
- Ensure all compressed air valves are in the correct position for normal running.
Note  The compressed air supply is the responsibility of others.

Manual Cleaning Operation

1. Select $!05(

2. Press $0#5
3. Filter start cleaning control relays K1 are now energised and relay contacts are now closed to allow
the following to occur simultaneously:
a) Provide a maintained contact across pushbutton contact S2.
b) Pulsing from the 32 way pulse control board PC1 (34TF-1). A total of 6 solenoids are operated
simultaneously with a 28.5 second interval between pulsing. Pulsing will begin at the upper level of
the filter modules and will sequentially pulse down the full height of the unit in a 30 minute cycle.
The sequential timer circuit board is designed to supply a series of short duration (100milliseconds)
pulses at a set interval (typically 28.5 seconds). The interval can be adjusted to suit working
experience on site subject to compressed air availability.
c) Cleaning in progress light H2 illuminates.
4. The pulse timer circuit board PC1 (34TF-1) is set to 32 outputs. When output 32 pulses, cleaning
cycle card transfer latching relay KL1 energises to produce the following:
a) Normally closed contact opens to prevent further pulsing of card PC1 (34TF-1).
b) Normally open contact closes to initiate pulsing on pulse timer circuit board PC2 (tag no. 34TF-2).
The pulse circuit timer board supplies equi-spaced 110V AC pulse outputs to each solenoid valve on the
filter. The cleaning cycle is complete when pulse output 64 (i.e.output number 32 on pulse timer circuit board
PC2 (tag no. 34TF-2)) is energised.
5. The cleaning cycle will stop when the clean cycle stop relay K6 is activated by the last pulse on PC2
(tag no. 34TF-2). Relay K1 de-energises, opening the K1 contact to the pulse control board PC1
(34TF-1).
The cleaning cycle in progress light will extinguish when K1 de energises

REV: 1 FIRST ISSUE MB SJH 07/01/13

AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:

Bassington Lane PULSE FILTER CONTROL SYSTEM 1
MB 07/01/13
Cramlington
SJH 07/01/13
GB00219848

  !"#

 
 
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 3 OF 6
GREENVILLE

Automatic Cleaning Operation

With selector switch S1 set to the $0$$0

mode with the exception that the pulse cleaning is initiated by either the:

i) Control differential pressure switch set points on PDIS1 (TF-1A).

ii) 24 hour time clock TR1.
iii) Remote start from end user.

i) Differential pressure control:

On rising differential pressure Photohelic indicator low pressure switch contact will close first and
then the high pressure switched contact will close. On closure of the upper level Photohelic
contact, relay K2 is energised and acts as a maintaining contact across the high pressure
Photohelic switched contact.
The system works as it would in the manual cleaning process from this point and the differential
pressure will continue to fall until the low pressure contact is activated. At this point the filter
cleaning will continue until the last pulse is activated and relay K6 pulses to reset the control
circuit.
This action ensures that all canister filter element pairs are cleaned evenly.
Start cleaning set-point = 3.0
Stop cleaning set-point = 2.5

ii) Time clock control:

The time clock is set to produce a pulsed output via time clock TR1 on a daily basis. When pulse
contact TR1 closes, filter cleaning control relay K1 is energised. The filter cleaning system will
pulse all canister filter element pairs until the last pulse activates relay K6 to reset the control
circuit.

iii) Remote start from end user

The remote start signal from the client energises K3 and starts pulsing. Pulsing will stop after one
full cycle is complete. If the remote signal is still present when the cycle is complete pulsing will
start again. This sequence will continue until the remote start signal is removed.

REV: 1 FIRST ISSUE MB SJH 07/01/13

AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:

Bassington Lane PULSE FILTER CONTROL SYSTEM 1
SJH 07/01/13
Cramlington
MW 07/01/13
GB00219848

  !"#

 
 
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 4 OF 6
GREENVILLE

Pulse sequence control:

It should be noted that pulsing initiated by either pushbutton or timer will result in one cleaning
cycle (one cycle = 64 pulse operations) in 30 minutes.
In the case of differential pressure control the filter pulsing may operate for several cycles
depending upon ambient conditions, dust loading and filter cartridge condition. Pulsing will only
stop when the filter differential pressure is below the low set point AND the last pulse is activated.

Counter P1
This counter displays the number of times the filter control system has been initiated.
It is non resettable.

REV: 1 FIRST ISSUE MB SJH 07/01/13

AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:

Bassington Lane PULSE FILTER CONTROL SYSTEM 1
SJH 07/01/13
Cramlington
MW 07/01
GB00219848

  !"#

 
 
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 5 OF 6
GREENVILLE

Screw Auger Operation

The purpose of the screw auger is to extract dust from the hoppers during pulse cleaning of the
canister filter element pairs.
The screw auger has an auto/manual switch, start and stop pushbuttons for maintenance
purposes on the filter control panel. Indication of screw running and tripped status is provided on
the filter control panel.
NB  Before any maintenance is undertaken on the screw the 3 phase supply must be isolated at
the filter control panel via MCB F1 or isolator Q1.

When selector switch is switched to 0$!6

1. Screw will start when start pushbutton is pressed. The screw will continue to run
until the stop pushbutton is pressed. When the screw is running the Screw Running
light will illuminate.
2. The screw will also stop running if an overload condition occurs. This will also
illuminate the Screw Overload Tripped light.

When selector switch is switched to 0$!6

1. When cleaning starts the screw will start running. The Screw Running light H4 will
illuminate.
2. When the cleaning cycle is complete the screw will continue to run until the run on
timer TR2 times out.
3. If the system is cleaning and the screw is running and an overload condition occurs
the screw will stop but the cleaning will continue. The Screw Overload Tripped light
H3 will illuminate.

With the above control it will be possible to start the cleaning sequence without the screw running.
It will also be possible to run the screw without the pulse sequence operating.

During normal operating conditions both selector switches shall be selected to 

The filtration system also includes the following additional instrumentation for remote monitoring at
the Gas Turbine Control Panel:

REV: 1 FIRST ISSUE MB SJH 07/01/13

AAF INTERNATIONAL SEQUENCE OF OPERATION FOR REV:

Bassington Lane PULSE FILTER CONTROL SYSTEM 1
SJH 07/01/13
Cramlington
MW 07/01/13
GB00219848

  !"#

 
 
CLIENT:
FIRST ORDER No. MF12064 GE PROJECT: SIDDHIRGANJ SHEET 6 OF 6
GREENVILLE

HIGH DIFFERENTIAL PRESSURE (MACHINE TRIP) (PDIT-001) (96TF-1)

This transmitter provides a 4-20mA signal (=0 to 107 0#4

HIGH DIFFERENTIAL PRESSURE (MACHINE TRIP) (PDIT-002) (96TF-2A)

This transmitter provides a 4-20mA signal (=0 to 107 0#4

HIGH DIFFERENTIAL PRESSURE (MACHINE TRIP) (PDIT-003) (96TF-2B)

This transmitter provides a 4-20mA signal (=0 to 107 0#ne control system

REV: 1 FIRST ISSUE MB SJH 07/01/13

  !"#

 WRIGHTS DOWSON GROUP
Green End, Gamlingay, Sandy, Bedfordshire, SG19 3LA
Tel.: (+44) 01767650294 Fax: (+44) 01767651149
www.dowsongroup.com

SCREW CONVEYOR MANUAL

FOR TRAINING
PURPOSES - ALL
BUT PAGES 1 AND 4
WERE DELETED

Page 1 of 32
Iss.02/13
 WRIGHTS DOWSON GROUP
Green End, Gamlingay, Sandy, Bedfordshire, SG19 3LA
Tel.: (+44) 01767650294 Fax: (+44) 01767651149
www.dowsongroup.com

1. DESCRIPTION
1.1. The conveyors might be of mild steel or stainless steel construction, unless otherwise
specified, and consist of a ‘U’ section trough with reverse flanges folded along top
edges. Tubular shafts are coupled together by means of a bolted coupling shaft,
which is supported in an intermediate bearing suspended from the top of the casing
by hangers. The drive and tail shafts are mounted in ball flange mounted bearings,
unless otherwise specified.

1.2. A diaphragm switch or any other material blockage protection device as may be
specified, might be fitted on the top of the conveyor near to the end outlet to
prevent damage to the conveyor should a blockage occur.

1.3. A rotation sensor might be fitted on tail end shaft to prevent damage to the
conveyor should a blockage occur.

1.4. The drive consists of a geared motor and chain drive complete with enclosed guard,
as standard. It might be fitted on top or side of the conveyor. Direct coupled geared
motors with flexible coupling can also be supplied.

GEARED MOTOR
PLATFORM

INLET
COVER
COVER
BRIDGE

FLIGHT
ON PIPE

GASKET
DRIVE END WITH CASING
BEARING, SEAL WITH SUPPORT
AND CHAIN GUARD OUTLET FEET
TAIL END WITH
BEARING AND SEAL

Page 4 of 32
Iss.02/13
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

SECTION 01
 O & M MANUAL DIVERTER

Diverter and Blanking plate 9F

Prepared for:

GE

BRADEN EUROPE B.V.

HEERLEN, THE NETHERLANDS

BE Project No
11068

Approved for Construction

Project: Siddhirganj

Document name: 11068/OM-01

Initials: Date: Sign: Initials: Date (approved): Sign: Rev.

R. Co 27-Sep-13 R. Müller-Courté E.C. 27-Sep-13 E. Cauberg B

 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Revision History

Revision Content of change Date

0 Internal version
A First issue
B Approved for Construction 27-Sep-13

Page 2
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Table of contents

Revision History ............................................................................................................ 2

Preface to operating & maintenance manual ............................................................... 5
1 Scope of supply ..................................................................................................... 6
1.1 General notes ................................................................................................. 6
1.2 Scope of the exhaust system ......................................................................... 6
2 Safety Information ................................................................................................. 7
2.1 General information........................................................................................ 7
2.1.1 Operating instructions ............................................................................. 7
2.1.2 Prevention of accidents/environmental protection.................................. 7
2.1.3 Staff ......................................................................................................... 7
2.1.4 Constructional modifications ................................................................... 7
2.2 Warranty ......................................................................................................... 7
3 Operation and Design ........................................................................................... 8
3.1 Operation........................................................................................................ 8
3.1.1 Important notes before start up .............................................................. 8
3.1.2 Remote operation ................................................................................... 9
3.1.3 Simple cycle operation ............................................................................ 9
3.1.4 Combined cycle operation ...................................................................... 9
3.1.5 Emergency operation ............................................................................ 10
3.1.6 Local operation ..................................................................................... 10
3.2 Application of seal air ................................................................................... 10
3.2.1 Operation .............................................................................................. 10
3.2.2 Application ............................................................................................ 11
3.3 Design .......................................................................................................... 11
3.4 Main components ......................................................................................... 11
3.4.1 Drive shaft ............................................................................................. 13
3.4.2 Seal air system ..................................................................................... 15
3.4.3 Blanking plate ....................................................................................... 16
Closing procedure............................................................................................ 16
Opening procedure .......................................................................................... 17
4 Transport and storage of spare parts .................................................................. 18
4.1 General......................................................................................................... 18
4.1.1 Short storage (< 2 month) ..................................................................... 18
4.1.2 Long storage (> 2 month) ..................................................................... 18
5 Maintenance and Repair ..................................................................................... 19
5.1 Maintenance schedule ................................................................................. 19
5.1.1 Time intervals........................................................................................ 19
5.1.2 Regular external inspections ................................................................ 19
Bearings: .......................................................................................................... 19
Differential pressure switches:......................................................................... 20
Seal Air Valves: ............................................................................................... 20
Seal Air Valve Actuator: ................................................................................... 20
Seal Air Piping: ................................................................................................ 20
Seal Air Fan: .................................................................................................... 20
Diverter Casing: ............................................................................................... 21
Drainage: ......................................................................................................... 21

Page 3
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Hydraulic Power Unit: ...................................................................................... 21

Electric Components:....................................................................................... 21
5.1.3 Regular Internal inspections ................................................................. 21
Landing Bars: ................................................................................................... 21
Liners: .............................................................................................................. 21
Stainless steel components: ............................................................................ 22
5.1.4 Lubricating ............................................................................................ 22
5.1.5 Settings ................................................................................................. 22
5.2 Preparation of repair work ............................................................................ 22
5.2.1 Spare parts ........................................................................................... 22
5.3 Blade seals ................................................................................................... 22
5.3.1 Blade seal removal ............................................................................... 23
5.3.2 Blade seal installation ........................................................................... 23
5.4 Shaft seals ................................................................................................... 23
5.4.1 Shaft seal removal ................................................................................ 23
5.5 Hydraulic cylinders ....................................................................................... 25
5.5.1 Removal of a hydraulic cylinder ............................................................ 25
5.5.2 Installation of a hydraulic cylinder......................................................... 25
5.6 Accumulators ............................................................................................... 25
5.6.1 Refilling of accumulators with nitrogen ................................................. 25
5.6.2 Replacement of accumulator bladder ................................................... 25
5.7 Tests after re-assembly ............................................................................... 26
5.7.1 Replacement of seals ........................................................................... 26
5.7.2 Replacement of shaft seals .................................................................. 26
5.7.3 Stroke readjustment of hydraulic cylinder ............................................ 26
6 Trouble Shooting ................................................................................................. 27

Page 4
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Preface to operating & maintenance manual

A Diverter performs a very critical function in a combined cycle power plant. The
reliable function and the proper performance are very important for the availability of
the entire gas turbine combined cycle power plant and the efficiency with which it can
operate.
Great care and effort have been invested into the design and manufacture of the
products at the plant. Our company offers many years of experience in designing,
fabricating and operating such equipment. The same care and consideration must be
given to the product when installing it in the field and putting it into operation as well
as for the operation and documentation.
We have documented in writing as much information and instructions about our
Diverter as possible. Nevertheless it is to be appreciated that it is almost impossible
to document years of experience gained in dealing with various circumstances world
over and hence we strongly recommend that the erection of the Diverter is carried
out under the supervision of Braden field service engineers.

M. Frinken
Managing Director

Page 5
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

1 Scope of supply

1.1 General notes

For the components described in this section, please refer to the Braden-Europe B.V.
General Arrangement Drawings 11068/A-01, and 11068/A-11; latest revision.

1.2 Scope of the exhaust system

On the Siddhirganjproject Braden Europe (B.E.) provides the diverter and the
blanking plate, see following typical sketch.

Item Description
A Diverter
B Blanking plate

Fig. 1.1: Typical setup of a diverter with blanking plate

Page 6
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

2 Safety Information

2.1 General information

2.1.1 Operating instructions

After the commissioning, the diverter damper is ready for operation.

The two main modes are:
− Simple cycle operation
− Combined cycle operation
The main steps of the diverter operating instruction, is described here after. The
control description of the PLC can be found in “Functional description” (11068/FD-
01).

2.1.2 Prevention of accidents/environmental protection

Movement of diverter blade while personnel are working inside the diverter can
cause serious injuries or even death.
− Before entering the diverter, the blade has to be moved to the HRSG closed
position and must be mechanically locked.
− To prevent accidental operation of the diverter, switch off the hydraulic unit
and relief the oil from the accumulators.

2.1.3 Staff

The staff working on the supplied exhaust system has to be familiar and trained to
work on hydraulic and electric installations.

2.1.4 Constructional modifications

After erection / commissioning no further modifications on the exhaust system are

allowed without the prior acceptance of B-E and/or the supervision of B-E technical
advisor.

2.2 Warranty

Warranty is granted in accordance to the order.

Full warranty applies only if the commissioning of the diverter- and blanking plate
system (i.e. actuators, hydraulic unit, fans and valves) has been performed by
Braden Europe. Also according Braden Europe quality plan 11068/QA-11 an
erection-documentation has to be prepared, including inspection reports signed off by
the quality assurance department from site. All quality requirements have to be met.
In case of non-fulfillment of all Braden Europe quality requirements, warranty
becomes void.

Page 7
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

3 Operation and Design

3.1 Operation

The purpose of the Diverter System is to direct the exhaust gases coming from the
Gas Turbine either
− to the Bypass Stack (when operating in Simple Cycle Mode), or
− to the Heat Recovery Steam Generator (when operating in Combined Cycle
Mode).

The auxiliary systems of the diverter contain the hydraulic unit, Seal air fans etc.

The wall design of the diverter casing and the duct for the blanking plate are similar.

The diverter and the blanking plate are dynamic systems with moving elements.

A diverter is a single bladed device installed in a Gas Turbine combined cycle plant
to divert the exhaust gas of the turbine either to a bypass stack or to a Heat
Recovery Steam Generator (HRSG). The Diverter is the most efficient system, which
includes multiple functions as follows:
− The safe shutoff of either bypass or HRSG-inlet.
− Turbine- / plant-protection due to the single-blade design, so that at no time
both gas passages can be closed.
− Control the gas flow during the HRSG start-up.
− Lowest possible pressure loss of all damper systems.
− A 100 % tight shut off of the exhaust gas will be achieved by using a double
seal system with seal air system.

3.1.1 Important notes before start up

Before GT start-up all drain valves in the diverter system have to be closed.
Disrespecting this requirement can cause serious damage to the equipment or
injuries to the staff.
− Include the diverter system drain into a “Permit to work” system, allowing
operation only when permission is granted.

Caution:
During gas turbine operation it is not possible to stop the blade in following positions
as programmed in the PLC:
− 0° - 10° before HRSG closed position
− 80° - 90° before bypass closed position

Page 8
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

In conjunction with the DCS, the software in the PLC controls the operations of the
damper. Before operating the diverter the following instructions have to be
considered:
− Before operating the actuator make sure that all four locking pins have been
removed.
− There are no obstacles for the moving parts of the damper at the in- and
outside.
− The use of the damper in intermediate positions is only permitted during
HRSG-startup and shut down. Using the damper in intermediate position is not
permitted, because it will drastically reduce the lifetime of the blade seals.
− When operating the seal air fans during gas turbine operation make sure that
the seal air valves are always closed before the fans are switched off. Non-
respect of this request can cause serious damages.
− Confirm before operation that all manholes are closed properly.
− The power switches of the Hydraulic Power Unit have to be on.
− The damper has to be released for desired operation mode.

3.1.2 Remote operation

This is the normal operating condition in which the damper will be used. The selector
switch at the HPU is to be switched to Automatic Mode (Remote Mode) and the
diverter system will operate automatically in response to the DCS command signal.
No local operation is possible.

3.1.3 Simple cycle operation

In this cycle the damper blade is in HRSG closed position. In this case the HRSG will
not be heated up.
In addition, for HRSG maintenance, the blanking plate must be moved to the HRSG
closed position. In this case it is necessary that the diverter blade is secured by all
four locking devices (2 per side).
B.E. drawing 11068F-A001-A001-000 sheet 3 shows the drive piston system with the
locking pins installed. In order to lock the blade, the locking pins must be inserted at
the indicated places. When not in use, the locking items are stored in the storage on
the side of the actuator system.

3.1.4 Combined cycle operation

This describes the operation with the blade in the bypass-closed position. This mode
describes the operation of the gas turbine and the HRSG system.

Page 9
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

3.1.5 Emergency operation

General
Emergency operation means; the fast closing of the blade from any position to the
HRSG-closed position. The damper can no longer be operated, after the emergency
signal has been given, until the emergency signal is released and a reset was made.
If the fast close signal came from the DCS, reset in the DCS. If the fast close signal
came from the PLC, reset in the Local Control System.
The emergency operation can be initiated externally (by HRSG system / GT system)
or internally (by hydraulic system).
− In case of an external fault, the “emergency command” will be forwarded from
the DCS to the PLC.
− An internal fault (low-low pressure in the accumulator) will be indicated to
DCS. DCS will return the “emergency” command to the PLC.

3.1.6 Local operation

Moving the diverter blade in “local operation mode” during gas turbine operation is
not allowed. Seriously damage to the plant equipment and severe injury to the staff
can occur.
Before starting in local operation, the blade must be moved to HRSG closed position
and all four locking pins must be installed on the actuator.
To prevent accidental operation of the damper blade during gas turbine operation,
implement a “Permit to work” system.

Basically the “local operation mode” should only be released for maintenance on the
damper and hydraulic system, when the gas turbine is shut off.

3.2 Application of seal air

The seal air system provides 100% gas tightness in both end positions of the blade.
Atmospheric air will be pressurized by a fan and flow in the seal air system.

3.2.1 Operation

The program implemented in the PLC mainly controls the seal air system.
To start the seal air system:
− If the key switch is put to automatic mode, the fan starts.
− After a delay, the fan will pressurize the seal air piping and the system will
check the end position of the blade by the limit switches.
− Next the appropriate seal air valve will open.
− The pressure in the seal air cavity is compared to the actual exhaust gas
pressure.
To switch the seal air off:
− Close all seal air valves
− Only when all valves are closed the seal air fan will be stopped

Page 10
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

3.2.2 Application

To prevent working personal inside the HRSG being exposed to leaking exhaust gas,
the following rules need to be followed:
− Before entering the HRSG start the seal air system and check that the seal air
pressure is at least 5mbar above exhaust gas pressure.
− Lock the diverter blade by installation of all four locking pins.
− Move blanking plate in HRSG closed position before entering HRSG.

− Monitor the seal air pressure continuously during maintenance work in HRSG.
In case of low pressure, evacuate the HRSG immediately.

3.3 Design

The Diverter is designed according the contract requirements, where gas pressure,
temperature, and wind loads, seismic loads etc. have been taken into consideration.
The calculations were done in accordance to DIN, UBC, and other applicable
standards.

3.4 Main components

The diverter consists of a T-shaped casing with one inlet and two outlets. The
diverter casing has internal insulation. Inside this casing an insulated movable blade
is installed. It rotates with hydraulic piston actuators.

For the diverter sealing, seal air fans, valves pipes and pressure indicators are
installed.

The blade controlling will be done by the HPU and DCS.

A position transmitter and a mechanical position indicator allow following up the

actual blade position.
To reach 100% gas tightness, seal air will be applied in both end positions. During
the seal air operation, a differential pressure transmitter permanently measures the
differential pressure between the seal air cavity and the exhaust gas system. To
assure the gas tightness the seal air differential pressure should be at least 50 mm
WC higher than the exhaust gas pressure

Page 11
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Item Description
01 Casing
02 Liner (Insulation cover)
03 Scallops and insulation
04 Drive system
05 Toggle linkage
06 Blade
07 Limit switch box
08 Spring package
09 Hydraulic cylinder

Fig. 3.1: typical diverter

Page 12
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

3.4.1 Drive shaft

Item Description
01 Bearing
02 Shaft seal

Fig. 3.2: typical drive shaft

− Toggle drive.
The blade is operated by a toggle drive system. The toggle linkages are designed
to swing the blade through 90° while the drive shaft that moves the toggle linkages
rotates through more than 90°. The system is equipped with high temperature
spherical bearings for the main shaft and for the connections of the drive arms to
the linkages and of the linkages to the blade.
− Shaft seals.
Where the shafts pass from the hot gas inside of the diverter to the ambient
outside, shaft seals are used. The seals are made of alloy material and are of a
labyrinth type.
− Actuation.
The diverter is driven hydraulically. The actuators are placed on both shaft ends.
These actuators are supported from the diverter casing using spring packages.
These spring packages that transmit the reaction moments to the casing and allow
thermal expansion of the shaft and the toggle linkage.

Page 13
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

− Drive shaft.
The drive shafts have been designed for the maximum occurring loads of the
diverter actuator system and are made of stainless steel with high allowable stress
figures at high temperature.
− Bearing.
All bearings used for the main shaft, pivot shafts and toggle linkage are spherical
bearings. These bearings allow tumbling and rotation on the same time
− Limit switches.
A set of 8 limit switches is connected directly to the pivot shaft: Four to indicate the
HRSG-closed position, four the HRSG-open position.
− Position transmitter.
There are two position transmitters that are connected directly to the pivot shaft.
They provide analog 4-20mA signals. One is wired to the local control panel; the
other one is wired directly to the DCS.
Calibrated values are:

4mA HRSG closed (0%)

20mA HRSG opened (100%)

− Blade locking.
The blade movement can be locked with four locking pins (two on each side);
applicable only in the HRSG-closed position.

Item Description
01 Locking pin
A Location when locked
B Location when not locked

Fig 3.3: Locking mechanism of blade

Page 14
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

− Internal insulation.
The internal insulation for the casing is made of a non-ceramic fiber material with a
density of 128 kg/m³ and has a total thickness of 150 mm.
The insulation of the blade is made of a non-ceramic fiber material with a density of
64 kg/m³ and has a total thickness of 100 mm.

The specialty of the insulation is the method Braden uses to fix the material to the
wall and to protect the liner plates against wears. The heat transfer to the outside is
reduced to a minimum by the special shape of the scallop bars. The scallop bars are
welded to the wall in a special pitch. At the same time the scallop bars secure the
position of the insulation material and the solid position of the liner plates.
The liner plates are fastened to the scallop bars by secured nuts. To protect the
liners against warping there are additional U-channels at the liner periphery. To allow
the occuring thermal expansion there are oblong holes in the liners.

3.4.2 Seal air system

Item Description
01 Seal air fan
02 Non return valve
03 Seal air piping
04 Seal air valves
05 Tightness control

Fig. 3.4: typical setup of a seal air system

Page 15
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

− Fans.
The fans are standard radial fans with direct mounted motors. They are
manufactured in steel construction. The impeller is directly mounted on the motor
shaft and is balanced dynamically. The position of the spiral casing is designed for
the lowest possible pressure drop. The motor has a terminal box suitable for direct
wiring.
− Non return valve.
Behind every fan a non-return valve is installed.
− Piping.
The piping, made of hot dip galvanized carbon steel up to the seal air valves, is
designed and manufactured for site assembly. Connections have to be done with
field clamps.
Supports for the piping are connected to the diverter casing.
− Seal air shut off valves.
The valves are designed for pressure and temperature requirements.
They are butterfly valves without flanges, suitable for the installation between two
counter flanges. The casing is of a cast material with outside shaft seals and
bearings. The sealing is effected by contact between the inside disc and a casing
landing bar.
The actuation is done by means of electric actuators directly connected to the drive
shaft. The actuator internal limit switches will provide signalization of the end
position.
− Tightness Control.
Differential Pressure switches measure the difference between the exhaust gas
pressure and the seal air pressure in the internal seal air cavity.

3.4.3 Blanking plate

Between the diverter damper and the HRSG, a blanking plate is provided to close the
HRSG inlet and allow safe personnel access into the HRSG.
A double safety barrier is created in the gas path toward the HRSG if:
− The diverter is in “HRSG closed” position.
− The seal air system is in operation.
− The blanking plate is closed.

To operate the blanking plate, at least 3 operators are required: 1 to operate the hoist
and 2 to guide the blade.

Closing procedure

Open the blanking plate cover on top, using the ratchet hoist.

Do not open the blanking plate cover unless

− the diverter blade is in “HRSG close” position
− the diverter blade is mechanically locked
− the seal air system is in operation

Not respecting this, can expose the personnel to leaking exhaust gas.
Secure the above mentioned safe situation in a “Permit to work” system.

Page 16
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

The mechanical locking devices of the blanking plate (one pin on each side), need to
be removed.
Lower the blanking plate cautiously. Check both sides regularly to prevent tilting of
the blade and damage on the blade seals. The “closed position” is reached when the
cover rests on the flange of the top cover.

Opening procedure

Do not start the opening procedure of the blanking plate unless

− the diverter blade is still in “HRSG close” position
− the diverter is mechanically locked
− the seal air system is still in operation

Not respecting this, can expose the personnel to leaking exhaust gas.
Secure the above mentioned safe situation in a “Permit to work” system.

Lift the blanking plate cautiously. Check both sides regularly to prevent tilting of the
blade and damage on the blade seals. When the upper position is reached, the two
locking pins of the blanking plate need to be installed.
Close the blanking plate cover on top using the ratchet hoist (use ladder tape to seal,
and re-install the flange bolts).

Item Description
01 locking pin

Fig. 3.5: typical blanking plate

Page 17
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

4 Transport and storage of spare parts

4.1 General

When the equipment arrives at the job site the contents of each shipment should be
compared with the Bill of Lading and Summary of Material/Packing List to verify that
all components have been received. If damage has occurred, the freight agent
should be notified at once. After inspection is complete, the material is ready for
unloading, either into a storage or installation area. The Summary of
Material/Packing List is a comprehensive list of all items shipped and is located
inside the crate containing the bolting hardware and small parts.

Any damage and shortage has to be reported to the BE office within two days after
arrival of goods at site. If BE is not notified it is assumed that everything has arrived
in good order.

4.1.1 Short storage (< 2 month)

For short storage on site the diverter should be isolated from the ground on leveled
beams and with an appropriate rain protection. Any accumulation of rainwater and/or
dust should be avoided. The actuators and electrical components should be stored in
a dry enclosed storage. For all components stored or installed outside it is required to
connect all heaters electrically. During storage, check the delivered items at a regular
base for unwanted accumulation of rainwater and/or dust.
The containers and/or crates with the loose parts should only be opened when
needed for erection. The damper should be stored away from normal access to
prevent damage by accidental collision.

4.1.2 Long storage (> 2 month)

If the storage exceeds a period of two months, additional precautions have to be

taken.
The storage of the diverter can be performed as described above.
Electrical equipment has to be stored as described in the attached storage
instructions given by the suppliers of the actuator/gearboxes (Auma), supplier of the
seal air fan, and suppliers of the instrumentation.

Page 18
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

5 Maintenance and Repair

5.1 Maintenance schedule

5.1.1 Time intervals

Every 3 months:
− Visual Inspection as indicated in § 5.1.2 (regular external inspections)

Every 6 months:
− Visual inspection as indicated in § 5.1.3 (regular internal inspections)
− External inspection as indicated in § 5.1.2 (regular external inspections) and
following the supplier manuals
− Grease bearings

Every 12 months:
− External and internal inspection as described in § 5.1.2, § 5.1.3 and following the
supplier manual.
− Inspect internal bearings visually.
− Inspect visually welds of the blade and drive system.

Quarter life inspection:

A full internal and external inspection should be made every 3.500 cycles or every 5
years, whatever comes first.
The quarter life inspection should to be carried out by a Braden-Europe specialist, to
assure that wear on parts of the equipment is recognized or analyzed correctly.

The quarter life inspection includes:

− The yearly inspection as described.
− A thorough inspection of all welds on the blade.
− A check of the insulation after removal of a reference area in a liner sheets (cut a
hole and inspect insulation below).
− Replacement of damaged insulation and liner.
− Inspection of the wall thickness and bottom thickness.
− Inspection of the torque tube welding.
− Inspection of the toggle welding and repair, if necessary.
− Repair of the welding.

5.1.2 Regular external inspections

Bearings:
− Any dirt or deposit in the area of the shaft must be removed and shafts must be
kept clean.
− Drive shaft bearings are provided with lubrication nipples. See chapter 5.1.4.

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 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Shaft seals:
− The shaft seals are labyrinth sealing systems to reduce the leakage to the outside.
− The seals are of pure metallic nature and are wear parts that need to be checked
for obvious damages and/or cracks.
− See Drawing 8801/A-03 & 8801/A-30.

Hydraulic drive system:

− Check for cleanliness of the system, especially of the cylinder rods.
− Check if all connection pins are secured.
− Check for leakages on hydraulic cylinders and connections.
− For lubricating of the bearings, see chapter 5.1.4.
− For the hydraulic cylinders please refer to BE 11068 001.2 in the Operating and
maintenance manual OM-02.

Limit switch arrangement:

− Check the correct fixation of the linkage.
− Check the correct fixation of the drive shaft and cams.
− Check the switch point of limit switch.
− Check the position transmitter by verification of amperage in closed and open
position.
− Please refer to: Drawing 11068X/N-02 and data sheets of the limit switch / Position
Transmitter.

Differential pressure switches:

− Check correct fixation.
− Check piping between differential pressure switches and pressure ports.
− Please refer to: Data sheet Pressure Switch and drawing 11068X/N-40.

Seal Air System:

− Please refer to drawing 11068G-A001-A001-000.

Seal Air Valves:

− Check correct opening and closing of the valves.
− Please refer to the Valve manual (BE 11068 004).

Seal Air Valve Actuator:

− Check correct fixation.
− Check setting of limit switch.
− Please refer to the Actuator manual (BE 11068 005).

Seal Air Piping:

− Check correct fixation.
− Check switchover-function of Seal Air Switch Valve.
− Check expansion joints.

Seal Air Fan:

− Check correct fixation.
− Check for excessive bearing noises.

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 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

− Inspect the shaft seals for excessive leakage.

− Check the housing for damages or cracks.
− For lubricating of the bearings of the fan, see chapter 5.1.4.
− Please refer to the Fan manual (BE 11068 003) especially for the inspection of the
impeller.

Diverter Casing:
− Check for damages and/or cracks.
− Check for discoloration.
− Check for leakage.

Drainage:
− Check drainage facilities.

Hydraulic Power Unit:

− Check piping to diverter including pipe connections, fittings.
− Check hoses for leakage or deformation.
− Check hydraulic unit for cleanliness.
− Check hydraulic unit for leakage.
− Check both pumps for excessive noises and/or vibrations.
− Check pressure of both pumps.
− Check for filter contamination.
− Check oil level.
− Please refer to BE 11068 001.2 in the Operating and maintenance manual OM-02.

Electric Components:
− Check for damages.
− Check if the components are clean.
− Check the cable connections.

5.1.3 Regular Internal inspections

Toggle Drive:
Check correct fixation of connection shafts.
Please refer to drawing 11068F-F001-A001-000.

Landing Bars:
Check for deformations of landing bars. Straighten if necessary.
Check cleanliness.
Check the gap seals.

Blade Seals:
Check for missing or damaged seals.
Please refer to drawing 81605/E-04.

Liners:
Liner plates need to expand at each startup.

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 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

− Check liner plates for missing bolts. Contact Braden-Europe if more than 3
bolts/studs are lost on the same liner plate.

Stainless steel components:

− Check for deformation or cracks. To repair a crack, a hole of Ø10mm is drilled at
the end of the crack to stop the crack of growing. Then weld the crack.

5.1.4 Lubricating

Item Interval lubricant

drive shaft bearings of diverter every 6 months Fuchs Renolit Unitemp 2
rod-end bearings of hydraulic every 6 months Fuchs Renolit Unitemp 2
cylinders
bearings of the seal air fan every 3 months Fuchs Renolit Unitemp 2

5.1.5 Settings

See the Instrument list in the additional documents of section 02.

5.2 Preparation of repair work

Before repair work is started, make sure it is save to perform service work on the
concerning equipment.
Persons working on the exhaust system can be seriously injured and equipment can
be damaged, if this ruled is not respected.
− Apply for permits to work on the equipment to be serviced.
− Follow local (national) and plant safety regulations.
− Use proper tools only.

The diverter is a very important component in the functioning of a combined cycle

power plant and should be treated accordingly.
All rotary components such as drive shafts, bearings, shaft seals and some
components exposed to turbulent flow and/or thermal stresses are subject to wear
and should be inspected regularly. It is suggested that external parts should be
visually examined at regular intervals.

5.2.1 Spare parts

These will be added later.

5.3 Blade seals

Blade seals are 0.5mm and 0.8 mm thick and have sharp corners / edges
If not handled carefully severe cuts on hands can occur
− Wear gloves during the handling of seals.
− Use proper tools only (ratchet -, ring, or jaw spanner 13mm). Do not use adjustable
spanners.

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 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

5.3.1 Blade seal removal

Identify the seals (see Seal drawing)

Disassemble Seals, Clamping bars and support bar

5.3.2 Blade seal installation

Install new seals (1, 2) with clamping bars (4), plate seals (5) and support bars (3).
Hand tightens bolts and nuts.
Adjust Seal length. The flat seals have slotted holes to adjust seal length. The correct
length in cold conditions corresponds to 25 mm overlapping at the landing bars.
Torque bolts and nuts with torque wrench to 25 Nm.
Secure nuts with counter nut.
Please refer to drawing: 82206/E-04

Item Description
01 Flat seal
02 Bias seal
03 Support bar
04 Clamping bar
05 Plate seal

Fig. 5.1: Blade seal installation

5.4 Shaft seals

For replacement of the shaft seals without dismantling the bearing it is necessary to
cut the new seals, which allows the installation without moving the bearing, see the
sketch below.

5.4.1 Shaft seal removal

Remove nuts and washers.

Move cover towards the bearing.

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 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Move seals with spacer.

Cut the damaged seals (2 cuts) and take them out.
Shaft seal installation
Place 3 new seals (2 inner seals with 1 outer seal in between), around the shaft.
Place the seals inside the spacer and place the spacer into the housing.
Place again 3 new seals (2 inner seals with 1 outer seal in between), around the
shaft.
Place the seals inside the spacer.

Item Description
01 Housing
02 Spacer
03 2 x Outer seal
04 Cover
05 4 x Inner seal

Note: Tighten with 30Nm and lock up with second nut

Fig 5.2: Shaft seal replacement

Page 24
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

5.5 Hydraulic cylinders

Before work on the hydraulic system can be performed the pressure of the system
has to be relieved. Hydraulic oil can leak out at high velocity, what can lead to
possible injuries and environmental pollution.
− Switch off the hydraulic unit. It is possible to relief the oil pressure in the
accumulators by opening the valve on the safety valve block.
Any maintenance on the cylinders has to be done in strict accordance to the
instructions of the cylinder supplier.

5.5.1 Removal of a hydraulic cylinder

Move the diverter blade to the HRSG closed position. Secure the position of the
blade by installing the locking pins. Relieve the hydraulic pressure.
Measure the length x (see sketch at paragraph 5.7.3) for aligning the new cylinder
Disconnect hydraulic hoses from cylinder and close connectors with plugs.
Secure the cylinder with a chain block in its position.
Remove the retaining ring at the rod side of the cylinder. Remove the connection pin.
Unbolt the foot point of the cylinder. Put the shim plates with the bolts aside.
Lift the cylinder with the chain block out the drive frame.
Remove the retaining ring at the piston side of the cylinder. Remove the connection
pin / support bracket and put aside with the retaining rings.

5.5.2 Installation of a hydraulic cylinder

Install the connection pin / support bracket with the retaining ring at the piston side of
the cylinder.
Lift the cylinder into the drive frame.
Install the support bracket with the original amount of shim plates into the drive
frame.
Install the connection pin at the rod side of the cylinder.
The stroke adjustment is explained in paragraph 5.7.3

5.6 Accumulators

5.6.1 Refilling of accumulators with nitrogen

If the nitrogen gas pressure is low, refill the accumulator using the supplied “filling
tool” in accordance with the procedure as described in the Operating and
maintenance manual OM-02 (BE 11068 001.2).

5.6.2 Replacement of accumulator bladder

If the accumulator bladder is damaged or every two years, replace the bladders as
per the replacement procedure given in the Operating and maintenance manual OM-
02 (BE 11068 001.2). Also refer to this manual for the refilling procedure.

Page 25
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

5.7 Tests after re-assembly

5.7.1 Replacement of seals

No tests required

5.7.2 Replacement of shaft seals

No tests required

5.7.3 Stroke readjustment of hydraulic cylinder

Make sure that all adjustment bolts of the cylinders are screwed out to the same
length. Not respecting this rule causes damage.
This is a very critical setting and should only be done by a Braden Europe specialist
or by another skilled technician.

Adjustment of cylinder in HRSG closed position.

This setting has been realized during commissioning and should not be readjusted.
Adjustment is only required if the cylinder has been replaced or disassembled.

x1 * l3
x≈ * 0 .5
l2

X Adjustment of the cylinder (see sketch)

l2 Length of the toggle lever 2705
l3 Radius of the outside actuator lever 600
X1 Measured distance between the landing bar
and the tip of the seal
All dimensions are in mm

Fig 5.3: Cylinder adjustment calculation

Lower the blade, relief the pressure of the system and turn out the adjusting bolt on
the cylinder. Move the blade against up and repeat the procedure until the seals are
in one plane with the landing bars.

Page 26
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

6 Troubleshooting

Component Findings Remedies

Shaft seals Excessive Leakage Check the correct assembly
Replace Seal Rings
Hydraulic Cylinders Oil Leakage Check correct tightening of fittings
Replace Seals
See Hydraulic Manual (BE 11068
001) incl. in 11068/OM-02
Re-machine Cylinder Bore
Refer to Hydraulic Manual (BE
11068 001) incl. in 11068/OM-02
Hydraulic Piping Oil Leakage Check correct tightening of fittings
Hydraulic Hoses Oil Leakage Check correct tightening of fittings
Replace Hoses
Damaged Hoses Replace Hoses
Limit Switch No signal from LS Check Linkage to Diverter Shaft
arrangement (Limit Switch) Check drive shaft and cam position
Check LS and replace if defective
Position Transmitter Wrong Feedback Check Linkage to Diverter Shaft
Signal Check drive shaft
Check Position Transmitter
See Manual (BE 11068 008)
Seal Air Valves Valve does not open Check the correct functioning of the
or close correctly. valve
See Valve Manual (BE 11068 004)
Check Correct Setting of Actuator
(LS and TS)
See Actuator Manual (BE 11068
005)
Check the Actuator (See Actuator
Manual (BE 11068 005))
Seal Air Fan Leakage of Exhaust Check Seal Air Valve
Gas
Excessive vibrations Check Fixation of Vibration
Dampers
Check free rotation of impeller
Check Cleanliness of Impeller
Rebalance dynamically the impeller
Refer to the Fan Manual (BE 11068
003)
Excessive Power Check Electrical Wiring
absorption Check Electrical Motor, see Fan
Manual (BE 11068 003)
Check tightness of diverter
See item 5.3

Page 27
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Component Findings Remedies

Diff Pressure Switch No Signal from Check tightness of diverter
Pressure Switches Check electrical Wiring
Check Differential Pressure
Switches
See Pressure Switch Manual (BE
11068 007).
Hydraulic Power Unit Diverter cannot be Check that mechanical Lock has
operated been removed
Check HPU for Readiness
Check Reset Button has been
pushed
Check Hydraulic Manual (BE 11068
001) incl. in 11068/OM-02.
Alarm Signal Check Local control panel and
hydraulic circuit and remedy
following Hydraulic Manual (BE
11068 001) incl. in 11068/OM-02
Fault Signal Check Local control panel and
hydraulic circuit and remedy
following Hydraulic Manual (BE
11068 001) incl. in 11068/OM-02
Accumulators not Accumulators cannot be charged:
working correctly Check safety valves following
Hydraulic Manual (BE 11068 001)
incl. in 11068/OM-02
Accumulators are charging and
discharging instantly.
Check correct opening of
Accumulator valves.
Check N2 pressure, recharge
bladders.
Replace bladders if necessary
following Hydraulic manual (BE
11068 001) incl. in 11068/OM-02
Check Hydraulic manual (BE 11068
001) incl. in 11068/OM-02
Electrical Problem Refer to the Hydraulic manual (BE
11068 001) incl. in 11068/OM-02
Diverter Not Tight Defective or Missing Replace Seals.
Seals
Diverter Blade not Check correct closing, contact of
closing correctly seals to landing bars
Check internal blade stop
Check stroke adjustment of
hydraulic Cylinders, see Hydraulic
Manual (BE 11068 001) incl. in
11068/OM-02

Page 28
 11068 Siddhirganj
MBR Exhaust System
9F Diverter and Blanking plate

Component Findings Remedies

Deformed Landing Straighten Landing bars
Bars
Liner Defects Unusual deformation Check that liner can expand freely,
of liner correct if necessary
Check that nuts are not too tight,
correct if necessary
Missing studs Install new studs, see enclosed
procedure
Leakages to outside Leakages at Retighten Flange bolting
expansion joints Repair or Replace Fabric
Expansion Joint
Cracks Repair cracks following procedure
Others / Diverter Contact Braden Europe B.V.
Others / HPU Refer to the Hydraulic Manual (BE
11068 001) incl. in 11068/OM-02
Others/Accessories Refer to the Product manuals

Page 29
Pump

This Drawing has had pages removed for training

purposes. Refer to original document for full details

General Electric International, inc.

Energy
Power Plant Engineering
 V cylinder : 92 ltr
V pipes : 50 ltr
V tank : 700 ltr
P e-motor 1/2 : 37 kW S1
e-motor 1/2 : 400 V 50 Hz
n2 1/2 : 1500 rpm
Q2 1/2 : 100 l/min
solenoid : 24 VDC

OPERATING PRESS RES

ps1 / ps2 / ps3 17 MPa accu pressure low 2 OF 3

both motors in operation valve 31 close
ps4 / ps5 / ps6 16 MPa accu pressure low low 2 OF 3
fast closing necessary
CYLINDER 150 / 100 x 1300 /- 25
CLOSE BOILER ANALOG E ps7
OPEN BOILER OPEN BOILER CLOSE BOILER ps7 22 MPa alarm over pressure

56 ltr accu

56 ltr accu

56 ltr accu

56 ltr accu
ps7 20.7 MPa stop pump
90 90 ps7 18 MPa start pump
ps7 17.5 MPa start other pump common alarm, operation valve 31 closed
60
90 12.8ltr 90
Po 70 5
-0 bar
61 23 ltr
62 63 OPERATING TIMES
250 bar 64 DN 25x2.5 normal open 60 sec
44 normal close 60 sec
fast close 20 sec

OPERATING TEMPERAT RES

Outside HP
Inside HP 95 50°C = start cooling
96
45°C = stop cooling
MC C MA A A B B MB
50 50 60°C = high temp. warning General Electric International, inc.
50 Energy
70°C = high high temp. > stop hydraulic pumps
Bx 11
Power Plant Engineering

Boiler open / close

B /B A /A
38.1 38.2 10
53-1 Ax
50
51

PS1 43 42
PS4 Ax Bx
36.1 36.2 10 11
53-2
28.1 28.2
50
51

PS2 34
PS5

29.1 29.2
53-3 32.2 Y10 67
50
51

PS3 49
PS6
32.1
Y9
53-4 220 bar 220 bar
51
50

PS7
RES 33.1 33.2 27.1 27.2

31 30.2 30.1
Y11
Y3-A Y3-B Y4-A Y4-B
open
165 bar 26.1 25.1 26.2 25.2 Q 60 l/min
53-5
51
50
COOLING/HEATING ON/OFF

COOLING/HEATING ON/OFF

COOLING/HEATING ON/OFF

PS8

24.1 24.2 70
OIL TEMP TOO HIGH

OIL TEMP TOO HIGH

OIL TEMP TOO HIGH

SF1 SF2
M10
22.1 22.2
OIL TEMP HIGH

OIL TEMP HIGH

OIL TEMP HIGH

220 bar 220 bar

23.1 23.2

21.1 21.2 50
lowlow

lowlow

lowlow

MT
20 47
low

low

low

50 50
6.1 6.2 6.3 T2 MP1
96 P1 MP2
96 P2 T1 57/58
9.1 9.2 FILLING POINT
SL1
5 M1 95 M2 95 SF3 12 SF4
ST1 SL1 ST1 SL1
ST1
13.1 18.1 13.2 18.2
4/3" 4/3" 4/3" 1/2" 1 1/4" 1"

15/16 17 15/16 17
4
14.1 14.2 4
3 8.1 8.2
1
 PART-LIST (ASSEMBLY DRAWING) PART-LIST (ASSEMBLY DRAWING)
Pos Qty. Description Suppl. Length Part Number Dwg Material Weight/Unit Pos Qty. Description Suppl. Length Part Number Dwg Material Weight/Unit
01 1 SHAFT SEAL ø30 - N/A 08801-A010-A001-001 Yes 2.7 kg 76 4 SEAL AIR SUPPORT 700 mm x 100 mm 8860-A002-A001-000 Yes 16 kg
02 2 SHAFT SEAL ø340 - N/A 08801-A010-A001-032 Yes 20.0 kg 77 5 Washer A 10.5 N/A DIN 125 - A 10.5 - St-Galv. St-Galv. 0.004 kg
03 1 FLANGE BEARING ø30 ø 100 mm / 31 mm - 40 mm 08802-A007-P001-003 Yes 1.0038 1.019 kg 78 48 Washer A 17 N/A DIN 125 - A 17 - St-Galv. St-Galv. 0.011 kg
04 2 BALL BEARING ARRANGEMENT ø340 BE03 N/A 08802-A021-A001-012 Yes 99.3 kg 79 32 Washer A 21 N/A DIN 125 - A 21 - A4 A4 0.017 kg
05 2 SHAFT ø 50 mm - 183 mm 08803A-A001-P007-000 Yes 2.4668 3 kg 80 184 Washer A 21 N/A DIN 125 - A 21 - St-Galv. St-Galv. 0.017 kg
06 2 SHAFT ø 50 mm - 271 mm 08803A-A001-P008-000 Yes 2.4668 4 kg 81 276 Washer A 25 N/A DIN 125 - A 25 - St-Galv. St-Galv. 0.032 kg
07 1 BLADE ARRANGEMENT 6000 mmx967 mm BE02 6735 mm 10075E-E001-A001-000 Yes 9088 kg 82 24 Washer A 37 N/A DIN 125 - A 37 - St-Galv. St-Galv. 0.092 kg
08 4 SPRINGPACKAGE SUPPORT 480 mm x 330 mm - 1125 mm 11068C-C023-A001-000 Yes 186 kg 83 8 Washer A 8.4 N/A DIN 125 - A 8.4 - St-Galv. St-Galv. 0.002 kg
09 1 BLANKING PLATE ARRANGEMENT - N/A 11068D-A001-A001-000 Yes 27328 kg 84 5 Spring Washer A 10 DIN 127 - A 10 - St-Galv. St-Galv. 0.003 kg
10 1 FIELD LINER ARRANGEMENT (11068D-D35-S01) - N/A 11068D-D035-A001-000 Yes 434 kg 85 48 Spring Washer A 12 DIN 127 - A 12 - A4 A4 0.004 kg
11 1 SUPPORT NO 5 ASSEMBLY 852 mm x 779.75 mm 1813 mm 11068V-B010-A001-000 Yes 491.704 kg 86 4 Spring Washer A 12 DIN 127 - A 12 - St-Galv. St-Galv. 0.004 kg
12 1 SUPPORT NO 7 ASSEMBLY 792 mm x 779.75 mm 1813 mm 11068V-B011-A001-000 Yes 485.119 kg 87 6 Spring Washer A 16 DIN 127 - A 16 - St-Galv. St-Galv. 0.010 kg
13 1 SUPPORT NO 6 ASSEMBLY 909.5 mm x 852 mm 1813 mm 11068V-B012-A001-000 Yes 547.680 kg 88 32 Spring Washer A 20 DIN 127 - A 20 - A4 A4 0.016 kg
14 1 SUPPORT NO 8 ASSEMBLY 909.5 mm x 852 mm 1813 mm 11068V-B013-A001-000 Yes 547.680 kg 89 16 Spring Washer A 20 DIN 127 - A 20 - St-Galv. St-Galv. 0.016 kg
15 1 SUPPORT No 10 852 mm x 779.75 mm 1813 mm 11068V-B014-A001-000 Yes 495.603 kg 90 8 Spring Washer A 8 DIN 127 - A 8 - St-Galv. St-Galv. 0.002 kg
16 1 SUPPORT NO 09 ASSEMBLY 852 mm x 729.75 mm 1813 mm 11068V-B015-A001-000 Yes 495.603 kg 91 16 Retaining rings for shaft DIN 471 - 50x2 DIN 471 - 50X2 St-Galv. 0.010 kg
17 2 LONGITUDINAL BEAM ASSEMBLY 550 mm x 546 mm - 5994 mm 11068V-B020-A001-000 Yes 831 kg 92 44 Hex-Head Bolt M20 95 DIN 6914 - M20 x 95 - 10.9 Galv. 10.9 Galv. 0.323 kg
18 3 TRAVERSE BEAM ASSEMBLY 554 mm x 550 mm - 6122 mm 11068V-B021-A001-000 Yes 834 kg 93 176 Hex-Head Bolt M24 110 DIN 6914 - M24 x 110 - 10.9 Galv. 10.9 Galv. 0.560 kg
19 4 GUIDE PLATE ASSEMBLY 500 mm x 60 mm 600 mm 11068V-B022-A022-000 Yes 81.165 kg 94 44 Hex Nut M20 DIN 6915 - M20 - 10 Galv. 10 Galv. 0.080 kg
20 2 LONGITUDINAL BEAM ASSEMBLY 595 mm x 310 mm - 2520 mm 11068V-B023-A001-000 Yes 349 kg 95 176 Hex Nut M24 DIN 6915 - M24 - 10 Galv. 10 Galv. 0.172 kg
21 8 U-SHAPE DIN 1026 UNP-120 - 2775 mm 11068V-P001-P010-000 Yes 1.0570 37 kg 96 88 DIN 6916 - 21 - C45 Galv. C45 Galv. 0.021 kg
22 12 U-SHAPE DIN 1026 UNP-120 - 2850 mm 11068V-P001-P011-000 Yes 1.0570 38 kg 97 352 DIN 6916 - 25 - C45 Galv. C45 Galv. 0.030 kg
23 8 U-SHAPE DIN 1026 UNP-120 - 1540 mm 11068V-P001-P013-000 Yes 1.0570 20 kg 98 48 Washer 13 DIN 9021 - 13 - A4 A4 0.022 kg
24 14 PLATE 100 mm x 12 mm - 160 mm 11068V-T001-P012-000 Yes 1.0570 1 kg 99 112 Washer BE03 N/A DIN 9021 - 17 - St-Galv No St-Galv. 0.041 kg
25 1 BOTTOM CORNER RIGHT 2328 mm x 2173 mm - 8500 mm 11068X-A001-C010-000 Yes 6533 kg 100 24 Washer 39 DIN 9021 - 39 - St-Galv. St-Galv. 0.522 kg
26 1 BOTTOM MIDDLE 3000 mm x 468 mm - 8500 mm 11068X-A001-C011-000 Yes 5195 kg 101 4 Cylinder Head Cap Screw M10 45 DIN 912 - M10 x 45 8.8 Galv. 0.041 kg
27 1 BOTTOM CORNER LEFT 2328 mm x 2173 mm - 8500 mm 11068X-A001-C012-000 Yes 6868 kg 102 16 Cylinder Head Cap Screw M16 40 DIN 912 - M16 x 40 A4 0.104 kg
28 1 SIDE WALL LEFT 3450 mm x 358 mm - 8500 mm 11068X-A001-C013-000 Yes 5756 kg 103 32 Hex-Head Bolt M20 100 DIN 931-1 - M20 x 100 - A4 A4 0.315 kg
29 1 TOP CORNER LEFT 3476 mm x 2421 mm - 8605 mm 11068X-A001-C014-000 Yes 9120 kg 104 2 Hex-Head Bolt M10 22 DIN 933 - M10 x 22 - 8.8 Galv. 8.8 Galv. 0.025 kg
30 1 TOP MIDDLE BACK 1921 mm x 1197 mm - 3000 mm 11068X-A001-C015-000 Yes 2133 kg 105 3 Hex-Head Bolt M10 40 DIN 933 - M10 x 40 - 8.8 Galv. 8.8 Galv. 0.036 kg
31 1 TOP MIDDLE FRONT 1921 mm x 593 mm - 3000 mm 11068X-A001-C016-000 Yes 1677 kg 106 4 Hex-Head Bolt M12 20 DIN 933 - M12 x 20 - 8.8 Galv. 8.8 Galv. 0.035 kg
32 1 TOP CORNER RIGHT 3476 mm x 2421 mm - 8605 mm 11068X-A001-C017-000 Yes 9012 kg 107 8 Hex-Head Bolt M12 22 DIN 933 - M12 x 22 - 8.8 Galv. 8.8 Galv. 0.037 kg
33 1 SIDE WALL RIGHT 3450 mm x 378 mm - 8500 mm 11068X-A001-C018-000 Yes 4404 kg 108 8 Hex-Head Bolt M12 25 DIN 933 - M12 x 25 - A4 A4 0.039 kg
34 1 DRAIN ASSAMBLY 2'' x - 11068X-C006-A002-000 Yes 41 kg 109 4 Hex-Head Bolt M16 30 DIN 933 - M16 x 30 - A4 A4 0.083 kg
35 2 SUPPORT FOR MANHOLE-PLATFORM 160 mm x 158 mm - 220 mm 11068X-C030-A001-000 Yes 11 kg 110 6 Hex-Head Bolt M16 40 DIN 933 - M16 x 40 - 8.8 Galv. 8.8 Galv. 0.100 kg
36 1 FIELD LINER ARRANGEMENT (11068C-D31-S01) - N/A 11068X-D031-A001-000 Yes 1246 kg 111 56 Hex-Head Bolt M16 50 DIN 933 - M16 x 50 - 8.8 Galv. 8.8 Galv. 0.116 kg
37 1 LIMIT SWITCH BOX x - 11068X-N002-A001-000 Yes 6 kg 112 24 Hex-Head Bolt M16 60 DIN 933 - M16 x 60 - 8.8 Galv. 8.8 Galv. 0.132 kg
38 1 DIFF. PRES. SWITCH ASS. x - 11068X-N004-A001-000 Yes 2 kg 113 84 Hex-Head Bolt M20 55 DIN 933 - M20 x 55 - 8.8 Galv. 8.8 Galv. 0.208 kg
39 1 LIMIT SWITCH BOX SUPPORT 1020 mm x 495 mm - 1220 mm 11068X-N020-A001-000 Yes 37 kg 114 16 Hex-Head Bolt M20 95 DIN 933 - M20 x 95 - 8.8 Galv. 8.8 Galv. 0.307 kg
40 3 PROFILE CLAMP 58mm-64mm (1163647) N/A 2056N-64-A001-000 No 0.1 kg 115 112 Hex-Head Bolt M24 110 DIN 933 - M24 x 110 - 10.9 Galv. 10.9 Galv. 0.516 kg
41 1 SEAL AIR FAN ARRANGEMENT 2270 mm x 1695 mm - 52572MN80355-A001-A001-000 Yes 3187 kg 116 2 Hex-Head Bolt M24 140 DIN 933 - M24 x 140 - 8.8 Galv. 8.8 Galv. 0.623 kg
42 4 LOCKING PIN 220 mm x 95 mm - 735 mm 80002A-F034-A001-000 Yes 19 kg 117 26 Hex-Head Bolt M24 55 DIN 933 - M24 x 55 - 8.8 Galv. 8.8 Galv. 0.321 kg
43 4 LOCKING PIN PARKING DEVICE 150 mm x 210 mm - 155 mm 80002A-F034-A002-000 Yes 5 kg 118 24 Hex-Head Bolt M36 120 DIN 933 - M36 x 120 - 8.8 Galv. 8.8 Galv. 1.404 kg
44 2 FIXATION PLATE 480 mm x 92 mm - 480 mm 80002A-F035-A001-000 Yes 18 kg 119 8 Hex-Head Bolt M8 25 DIN 933 - M8 x 25 - 8.8 Galv. 8.8 Galv. 0.015 kg
45 2 SPRING PACKAGE 800mm 50.2kN 263 mm x 261 mm - 917 mm 80005-A001-A001-000 Yes 82 kg 120 5 Hex Nut M10 DIN 934 - M10 - 8 Galv. 8 Galv. 0.012 kg
46 2 SPRING PACKAGE 1550mm 50.2kN 261 mm x 263 mm - 1631 mm 80005-A003-A001-000 Yes 101 kg 121 48 Hex Nut M12 N/A DIN 934 - M12 x 1 A4 0.017 kg
47 8 CONNECTION SHAFT ø50 mm BE02 120 mm 80006-F044-P001-000 Yes 1.4057 2 kg 122 80 Hex Nut M16 DIN 934 - M16 - 8 Galv. 8 Galv. 0.034 kg
48 16 DISTANCE RING ø54 mmx2 mm BE02 13 mm 80006-F044-P002-000 Yes 1.0038 0 kg 123 100 Hex Nut M20 DIN 934 - M20 - 8 Galv. 8 Galv. 0.067 kg
49 4 SPRING PACKAGE SUPPORT 225 mmx140 mm 270 mm 80006-F045-A001-000 Yes 13 kg 124 32 Hex Nut M20 DIN 934 - M20 - A4 A4 0.065 kg
50 8 SHIM PLATE 215 mmx2 mm BE02 270 mm 80006-F045-P003-000 Yes 1.4512 1 kg 125 112 Hex Nut M24 DIN 934 - M24 - 10 Galv. 10 Galv. 0.113 kg
51 8 SHIM PLATE 215 mmx3 mm BE01 270 mm 80006-F045-P004-000 Yes 1.4512 1 kg 126 26 Hex Nut M24 DIN 934 - M24 - 8 Galv. 8 Galv. 0.113 kg
52 8 CONNECTION PLATE 60 mmx10 mm 210 mm 80006-F045-P005-000 Yes 1.0038 1 kg 127 24 Hex Nut M36 N/A DIN 934 - M36 - 8 Galv. 8 Galv. 0.405 kg
53 2 THERMO-INSULATION TOGGLE INSULATION N/A x N/A - N/A 80014A-F030-B001-000 Yes 108 kg 128 8 Hex Nut M8 N/A DIN 934 - M8 - 8 Galv. 8 Galv. 0.005 kg
54 1 TOGGLE ARRANGEMENT (WELDED) 3240 mm x 610 mm - 6110 mm 81600-F011-A002-001 Yes 2957 kg 129 8 PIPE CLAMP WITH RUBBER INSERT Ø350 (10 35 2770) JACOB P010-035-2770 No 1 kg
55 4 PLATE 50 mm x 12 mm BE01 104 mm 81600-F011-P005-001 Yes 1.4878 0 kg 130 3 Welded pipe DN-350 x 2000 (11 35 2010) 1984 mm JACOB P011-035-2010 No St-Galv. 17 kg
56 2 PLATE 60 mm x 12 mm BE01 360 mm 81600-F011-P006-001 Yes 1.4878 1 kg 131 1 Welded pipe DN-350 x 1000 (11 35 2020) 984 mm JACOB P011-035-2020 No St-Galv. 9 kg
57 4 PLATE 194 mm x 25 mm BE01 390 mm 81600-F012-P001-001 Yes 1.4878 3 kg 132 2 Welded pipe DN-350 x 500 (11 35 2030) 486 mm JACOB P011-035-2030 No St-Galv. 4 kg
58 4 BENDED PLATE ø 58 mm x 3 mm BE01 35 mm 81600-F012-P002-000 Yes 1.4512 0 kg 133 3 Welded pipe DN-350 x 200 (11 35 2040) 200 mm JACOB P011-035-2040 No St-Galv. 2 kg
59 4 BENDED PLATE ø 58 mm x 3 mm BE01 21 mm 81600-F012-P003-000 Yes 1.4512 0 kg 134 3 Push-in pipe DN-350 (11 35 2110) 990 mm JACOB P011-035-2110 Yes St-Galv. 13 kg
60 4 KEY 80 mm x 40 mm BE01 540 mm 81600-F014-P002-001 Yes 1.4878 13 kg 135 2 Push-in pipe DN-350 (11 35 2120) 492 mm JACOB P011-035-2120 Yes St-Galv. 6 kg
61 2 LINKAGE 150 mm x 130 mm - 2430 mm 81600-F017-A001-001 Yes 105 kg 136 2 Inspection pipe DN-350 (11 35 2190) 200 JACOB P011-035-2190 Yes St-Galv. 3 kg
62 1 SHAFT ø 340 mm - 1945 mm 81610-F015-P001-000 Yes 1.4878 1367 kg 137 1 T-piece DN-350 (11 35 2240) 550 mm JACOB P011-035-2240 No St-Galv. 8 kg
63 1 SHAFT ø 340 mm BE01 1945 mm 81610-F015-P002-000 Yes 1.4878 1369 kg 138 3 Segment 45° DN-350 (11 35 2330) JACOB P011-035-2330 No St-Galv. 2 kg
64 4 PARALLEL KEY 80 mm x 40 mm BE01 340 mm 81610-F015-P003-000 Yes 1.0503 8 kg 139 1 Bend 90° R=1D DN-350 (11 35 2339) JACOB P011-035-2339 No St-Galv. 7 kg
65 2 DRIVE ARRANGEMENT 1594 mm x 640 mm - 5570 mm 81680-F021-A003-000 Yes 2673 kg 140 22 PULL RING (Assembly) DN-350 12 35 2383 - JACOB P312-035-2383 No 1 kg
66 1 SEAL AIR SWITCH BOX DN 350 715 mmx522 mm BE02 920 mm 8817-A035-A001-000 Yes 75 kg 141 18 U-SHAPED SEAL (For pipe flange) DN-350 10 35 7951 - JACOB-P010-035-7951 No Silicone 0 kg
67 1 SEAL AIR DN350 (Boiler Side) 402 mmx505 mm BE02 1678 mm 8817-B014-A001-000 Yes 52 kg 142 4 RING SEAL (For push in pipe )DN-350 10 35 7155 - JACOB-P010-35-07155 No Silicone 0 kg
68 1 SEAL AIR DN350 (ByPass Side 45º) 547 mmx505 mm BE02 1678 mm 8817-B022-A001-000 Yes 65 kg 143 2 JASTA BUTTERFLY-VALVE ø350 BE02 N/A JASTA GD-6 LB DN-350 No 39.5 kg
69 4 FUNNEL INLET SIDE PIECE DN350 229 mmx201 mm BE03 356 mm 8817-B024-A001-001 Yes 4 kg 144 3 MPC-Railconsole 27/18 L=500mm (118888) BE03 N/A MPC-27_18-0500-A000 No 0 kg
70 2 FUNNEL INLET MIDDLE PIECE DN350 356 mmx201 mm BE03 1182 mm 8817-B024-A002-001 Yes 24 kg 145 4 MPC Systemrails (129883) BE02 N/A MPC-27_18-1000-000 Yes 1.0038 1 kg
71 1 HEAT PROTECTION 560 mmx110 mm BE02 1684 mm 8817-B030-A001-000 Yes 30 kg 146 4 MPC Grider cleat M6 (130281) BE03 N/A MPC-27_18-M6-A001 No 167.130 g
72 2 CONNECTION PIPE DN350 - Ø505 mm x 62 mm 8817-B044-A001-000 Yes 10 kg 147 4 HAMMERHEAD BOLT M8x30 (115152) BE02 N/A MPC-M8X30-A001-000 No 0 kg
73 4 GASKET DN350 - ø415 mm/356 mmx3 mm BE02 415 mm 8817-R014-P001-000 Yes Fibrefrax 0 kg 148 2 AUMA ACTUATOR SG05.1-22 BE02 N/A SG05.1-22 No %% 40.0 kg
74 4 LADDER TAPE 50 x 3 mm BE02 3682 mm 8817-T030-P004-000 Yes Fibrefrax 1 kg 149 2 SHAFT (BLADE BEARING) ø 98 mm - 390 mm ST-804-1 P006 Yes 1.4550 22.3 kg
75 1 PRESSURE SWITCH ARRANGEMENT 300 mmx221 mm - 360 mm 8827-A001-A001-000 Yes 6 kg

FL
O
W
C ADDED TEXT ON SHEET 7 C.L. H.J. RMuller 21-Jun-13
B ADDED MISSING BALLOONS C.L. H.J. RMuller 10-Jun-13
A FIRST ISSUE C.L. W.S. CLinkens 04-Jun-13
REV: AMENDMENT: DRAWN: CHECKED: APPROVED: APPRV'D DATE:
This document is property of BRADEN-EUROPE B.V. and if and in sofar
as othewise agreed in writing. It is put at the receivers disposal without BRADEN-EUROPE B.V.
consideration other than the receivers agreement that it shall not be copied, BRADEN
reproduced, lent or disposed of directly or indirectly nor used for any purpose Grasbroekerweg 114
other than that for which it is specifically furnished and that it is to be returned 6412 BH Heerlen
to BRADEN-EUROPE B.V. on demand together with copies made. The Netherlands

CLIENT: GENERAL ELECTRIC Title: GENERAL ARRANGEMENT

TOLERANCES: DIN 7168-g (T1) & DIN ISO 13920 Part Number : 11068-A001-A001-000

EUROPEAN PROJECTION WELDINGS ACCORDING TO DIN EN ISO 22553

GENERAL ARRANGEMENT x x SHEET No: 1 OF 10

N/A x N/A FILE NAME: SIZE: REV:

SCALE: 1: 50 11068-A001-A001-000.dwg A1 C
C:\Vault\Projects\11\110\11068\_Dwg\11068-A001-A001-000.dwg
 PART-LIST (ASSEMBLY DRAWING)
Pos Qty. Description Suppl. Length Part Number Dwg Material Weight [kg]
7446 01 1 SUPPORT STRUCTURE LEFT 581 mm x -325 mm - 9140 mm 11068D-C014-A001-000 Yes 1099.19
02 1 SUPPORT STRUCTURE RIGHT 581 mm x 325 mm - 9140 mm 11068D-C015-A001-000 Yes 1099.19
7076 03 1 SUPPORT STRUCTURE TOP 375 mmx330 mm - 7096 mm 11068D-C016-A001-000 Yes 1320.94
04 2 GUIDE 260 mmx174 mm - 6569 mm 11068D-C017-A001-000 Yes 195.89
5000 05 2 PIPE SUPPORT 480 mmx390 mm - 775 mm 11068D-C020-A001-000 Yes 111.59
3760 06 1 CONNECTION PIPE 385 mmx180 mm - 7211 mm 11068D-C023-A001-000 Yes 126.97
07 2 PIN 60 mmx60 mm - 100 mm 11068D-C025-A001-000 Yes 1.58
1425 08 2 PIN 172 mmx60 mm - 172 mm 11068D-C026-A001-000 Yes 2.25
979 09 2 STACK CONNECTION 450 mmx380 mm - 1675 mm 11068D-C027-A001-000 Yes 237.69

DETAIL A3 B3 10 1 RAIN PROTECTION 756 mm x 725 mm - 1158 mm 11068D-C030-A001-000 Yes 31.07

A5 11
12
1 BOTTOM ASSEMBLED 2354 mmx2233 mm
1 WALL LEFT ASSEMBLED 2354 mmx866 mm
-
-
7182 mm
3150 mm
11068D-D011-A001-000 No
11068D-D012-A001-000 No
6592.89
2064.53
A3 13
14
1 TOP ASSEMBLED 2354 mmx1654 mm
1 WALL RIGHT ASSEMBLED 2354 mmx866 mm
-
-
6926 mm
3150 mm
11068D-D013-A001-000 No
11068D-D014-A001-000 No
5746.93
2064.53

1530
15 1 FIELD LINER ARRANGEMENT (11068D-D31-S01) - N/A 11068D-D031-A001-000 Yes 235.52
16 1 BLADE FRAME 6028 mm x - 11068D-E001-A001-000 Yes 5398.66
OPEN BEFORE
LIFTING.
B3 DETAIL B3 17
18
1 LADDERTAPE 50x3
1 LIMIT SWITCH ACTUATOR 760 mm x 466 mm
BE02
-
15000
647 mm
11068D-LADDERTAPE No
11068D-N001-A001-000 Yes
Fibrefrax
34.88
0

19 1 LIMIT SWITCHES SUPPORT 483 mm x 300 mm - 1855 mm 11068D-N001-A002-000 Yes 81.02

20 1 LIMIT SWICHT SUPPORT 475 mm x 380 mm - 1315 mm 11068D-N001-A004-000 Yes 47.27
21 2 ACTUATOR NOCK (UPPER) 467 mm x 324 mm 1003 mm 11068D-N001-A007-000 32.03
22 2 ACTUATOR NOCK (LOWER) 185 mm x 160 mm 780 mm 11068D-N001-A008-000 30.31
23 1 LIMIT SWITCH BOX (ARRANGEMENT) 427 mm x 424 mm 349 mm 11068D-N002-A001-000 Yes 20.43
24 1 LIMIT SWITCH BOX (ARRANGEMENT) 427 mm x 424 mm 349 mm 11068D-N002-A002-000 Yes 10.37

A3 A5 25 1 LIMIT SWITCH BOX (ARRANGEMENT) 447 mm x 405 mm 868 mm 11068D-N002-A003-000 Yes 15.35
26 2 U-SHAPE DIN 1026 UNP-100 - 600 mm 11068D-P006-P001-000 Yes 1.0577 12.62
27 2 WASHER ø180.0 mm/115.0 mm t=6.0 mm - N/A 11068D-T002-P018-000 Yes 1.0577 1.42
CHAIN HOIST HOOK 28 2 CONNECTION-PLATE 80 mmx20 mm - 2135 mm 11068D-T002-P021-000 Yes 1.0577 52.67
ALWAYS HOOKED. 29 8 SHIM PLATE 120 mmx2 mm BE02 430 mm 11068D-T002-P022-000 Yes 1.4541 6.06
30 8 SHIM PLATE 120 mmx3 mm BE02 430 mm 11068D-T002-P023-000 Yes 1.4541 9.09
31 8 SHIM PLATE 120 mmx10 mm - 430 mm 11068D-T002-P024-000 Yes 1.0577 30.11
32 4 U-SHAPE 100 mmx40 mm - 450 mm 11068D-T005-P003-000 Yes 1.0577 16.33
33 4 SPLIT PING (FOR SHAFT ø 35mm) x7 mm - 130 mm 11068D-Z001-P002-000 No St-Galv. 0.4

E3 E3
34 2 RATCHET HADEF 750kg (Lifting length 2500mm) x BE02 11068D-Z001-P003-000 No %% 40
35 2 PIPE ASSEMBLY 215 mm x 114 mm - 2040 mm 80013-E001-A057-000 Yes 37.54
DETAIL A4 36
37
12 Washer A 10.5
24 Washer A 17
N/A
N/A
DIN 125 - A 10.5 - St-Galv.
DIN 125 - A 17 - St-Galv.
St-Galv.
St-Galv.
0.04
0.27
38 24 Washer A 21 N/A DIN 125 - A 21 - St-Galv. St-Galv. 0.41

9140
39 32 Washer A 25 N/A DIN 125 - A 25 - St-Galv. St-Galv. 1.03
40 12 Spring Washer A 10 DIN 127 - A 10 - St-Galv. St-Galv. 0.03
41 4 Spring Washer A 12 DIN 127 - A 12 - A4 A4 0.02
42 16 Spring Washer A 20 DIN 127 - A 20 - St-Galv. St-Galv. 0.26
44 16 Hex-Head Bolt M16 BE03 80 DIN 6914 - M16 x 80 - 10 No 10.9 Galv. 2.8
45 64 Hex-Head Bolt M24 120 DIN 6914 - M24 x 120 - 10.9 Galv. 10.9 Galv. 38.09
46 16 Hex Nut M16 BE03 DIN 6915 - M16 - 10 Galv No 10 Galv. 0.76
47 64 Hex Nut M24 DIN 6915 - M24 - 10 Galv. 10 Galv. 10.99
48 32 Washer DIN 6916 - 17 - C45 Galv. C45 Galv. 0.45
49 128 Washer DIN 6916 - 25 - C45 Galv. C45 Galv. 3.9
50 4 Washer 13 DIN 9021 - 13 - A4 A4 0.09
51 140 Washer 17 DIN 9021 - 17 - St-Galv. St-Galv. 5.73

A6 52 12 Hex-Head Bolt M10 30 DIN 933 - M10 x 30 - 8.8 Galv. 8.8 Galv. 0.36

18014
53 4 Hex-Head Bolt M12 50 DIN 933 - M12 x 50 - A4 A4 0.24
A6 DETAIL C3 54 12 Hex-Head Bolt M16 45 DIN 933 - M16 x 45 - 8.8 Galv. 8.8 Galv. 1.3
55 24 Hex-Head Bolt M16 50 DIN 933 - M16 x 50 - 8.8 Galv. 8.8 Galv. 2.78
2401

56 92 Hex-Head Bolt M16 60 DIN 933 - M16 x 60 - 8.8 Galv. 8.8 Galv. 12.11
57 4 Hex-Head Bolt M20 60 DIN 933 - M20 x 60 - 8.8 Galv. 8.8 Galv. 0.88
58 16 Hex-Head Bolt M20 75 DIN 933 - M20 x 75 - 10.9 Galv. 10.9 Galv. 4.12

DETAIL D3
59 8 Hex-Head Bolt M24 85 DIN 933 - M24 x 85 - 10.9 Galv. 10.9 Galv. 3.42
60 12 Hex Nut M10 DIN 934 - M10 - 8 Galv. 8 Galv. 0.14
61 4 Hex Nut M12 N/A DIN 934 - M12 - A4 A4 0.07
63 36 Hex Nut M16 DIN 934 - M16 - 8 Galv. 8 Galv. 1.24

DETAIL A1 64 16 Hex Nut M20 N/A DIN 934 - M20 - 10 Galv. 10 Galv. 1.06
13466

A6 65 4 Hex Nut M20 DIN 934 - M20 - 8 Galv. 8 Galv. 0.27

1922

1721
A6 66
67
40 Hex Nut M24
8 THREADED ROD M24 L=600.0 mm - N/A
DIN 934 - M24 - 10 Galv.
11068D-Z001-P001-000 No
10 Galv.
10.9
4.52
17.03
-
B4
68 1 CHAIN HOIST N/A E-440-68-00-10 Yes N0 MATERIAL 0

A4 69 4 ANGLE DIN 1028 - L 60 mm x 60 mm x 6 mm - 300 mm 11068D-P006-P012-000 Yes 1.0577 6.34

979
A4 B4
FIELD LINER DETAIL ( 1 : 5 )

6710 INSIDE DUCT.

6400 GASPATH.
( FOR PLACEMENT OF FILED LINERS SEE DRW. 11068D-D31-S01)
( FOR PLACEMENT OF FIELD LADING BARS SEE DRW. 11068D-L02-S01)

3450
FLOW FLOW

FLOW FLOW

FIELD LINER DETAIL

3823

15

2173
TYP.

ATTENTION: DO NOT DEFORM

700 6400 GASPATH. INTERLOCKING EDGES
2045 FOR ENDSTOPS PLACEMENT SEE DRW.: 11068D-G01-S01TILL S04 6710 INSIDE DUCT. OF LADING BAR
3000 3528 3528 DURING ASSEMBLY ON SITE.

DETAIL A1 ( 1 : 5 )
56 51

C ADDED DETAILS C.L. W.S. CLinkens 03-Jun-13

B ADDED PARTS 66 AND 67 C.L. H.J. RMuller 24-May-13
A FIRST ISSUE C.L. H.J. RMuller 07-May-13
REV: AMENDMENT: DRAWN: CHECKED: APPROVED: APPRV'D DATE:
This document is property of BRADEN-EUROPE B.V. and if and in sofar
as othewise agreed in writing. It is put at the receivers disposal without BRADEN-EUROPE B.V.

17 13 consideration other than the receivers agreement that it shall not be copied,
reproduced, lent or disposed of directly or indirectly nor used for any purpose
BRADEN Grasbroekerweg 114
6412 BH Heerlen
other than that for which it is specifically furnished and that it is to be returned
to BRADEN-EUROPE B.V. on demand together with copies made. The Netherlands

CLIENT: GENERAL ELECTRIC Title: BLANKING PLATE

TOLERANCES: DIN 7168-g (T1) & DIN ISO 13920 Part Number : 11068D-A001-A001-000

EUROPEAN PROJECTION WELDINGS ACCORDING TO DIN EN ISO 22553

BLANKING PLATE ARRANGEMENT x N/A SHEET No: 1 OF 7

N/A x N/A FILE NAME: SIZE: REV:

SCALE: 1: 50 11068D-A001-A001-000.dwg A1 C
C:\Vault\Projects\11\110\11068\11068D\_Dwg\11068D-A001-A001-000.dwg 2011-09-19 - 10-00-55
General Electric International, inc.
Energy
Power Plant Engineering
General Electric International, inc.
Energy
Power Plant Engineering
General Electric International, inc.
Energy
Power Plant Engineering
 General Electric International, inc.
Energy
Power Plant Engineering
CLOSE BOILER
OPEN BOILER OPEN BOILER CLOSE BOILER

C A A B B

Bx

Ax

T2 P1 P2 T1
 PART-LIST (ASSEMBLY DRAWING)
Pos Qty. Description Suppl. Length Part Number Dwg Material Weight/Unit
01 1 SEAL AIR FAN ARRANGEMENT 2270 mm x 1695 mm - 52572MN80355-A001-A001-000 Yes 3187 kg
02 1 SEAL AIR SWITCH BOX DN 350 715 mmx522 mm BE02 920 mm 8817-A035-A001-000 Yes 75 kg
03 1 SEAL AIR DN350 (Boiler Side) 402 mmx505 mm BE02 1678 mm 8817-B014-A001-000 Yes 52 kg
04 1 SEAL AIR DN350 (ByPass Side 45º) 547 mmx505 mm BE02 1678 mm 8817-B022-A001-000 Yes 65 kg
05 4 FUNNEL INLET SIDE PIECE DN350 229 mmx201 mm BE03 356 mm 8817-B024-A001-001 Yes 4 kg
06 2 FUNNEL INLET MIDDLE PIECE DN350 356 mmx201 mm BE03 1182 mm 8817-B024-A002-001 Yes 24 kg
07 1 HEAT PROTECTION 560 mmx110 mm BE02 1684 mm 8817-B030-A001-000 Yes 30 kg
08 2 CONNECTION PIPE DN350 - Ø505 mm x 62 mm 8817-B044-A001-000 Yes 10 kg
09 4 GASKET DN350 - ø415 mm/356 mmx3 mm BE02 415 mm 8817-R014-P001-000 Yes Fibrefrax 0 kg
10 4 LADDER TAPE 50 x 3 mm BE02 3682 mm 8817-T030-P004-000 Yes Fibrefrax 1 kg
11 1 PRESSURE SWITCH ARRANGEMENT 300 mmx221 mm - 360 mm 8827-A001-A001-000 Yes 6 kg
12 4 SEAL AIR SUPPORT 700 mm x 100 mm 8860-A002-A001-000 Yes 16 kg
13 8 PIPE CLAMP WITH RUBBER INSERT Ø350 (10 35 2770) JACOB P010-035-2770 No 1 kg
14 3 Welded pipe DN-350 x 2000 (11 35 2010) 1984 mm JACOB P011-035-2010 No St-Galv. 17 kg
15 1 Welded pipe DN-350 x 1000 (11 35 2020) 984 mm JACOB P011-035-2020 No St-Galv. 9 kg
16 2 Welded pipe DN-350 x 500 (11 35 2030) 486 mm JACOB P011-035-2030 No St-Galv. 4 kg
17 3 Welded pipe DN-350 x 200 (11 35 2040) 200 mm JACOB P011-035-2040 No St-Galv. 2 kg
18 3 Push-in pipe DN-350 (11 35 2110) 990 mm JACOB P011-035-2110 No St-Galv. 13 kg
19 2 Push-in pipe DN-350 (11 35 2120) 492 mm JACOB P011-035-2120 No St-Galv. 6 kg
20 2 Inspection pipe DN-350 x 200 (11 35 2190) 200 mm JACOB P011-035-2190 No St-Galv. 3 kg
21 1 T-piece DN-350 (11 35 2240) 550 mm JACOB P011-035-2240 No St-Galv. 8 kg
22 3 Segment 45° DN-350 (11 35 2330) JACOB P011-035-2330 No St-Galv. 4 kg
23 1 Bend 90° R=1D DN-350 (11 35 2339) JACOB P011-035-2339 No St-Galv. 7 kg
24 22 PULL RING (Assembly) DN-350 12 35 2383 - JACOB P312-035-2383 No 1 kg
25 4 RING SEAL (For push in pipe )DN-350 10 35 7155 - JACOB-P010-35-07155 No Silicone 0 kg
26 18 U-SHAPED SEAL (For pipe flange) DN-350 10 35 7951 - No Silicone 0 kg
27 2 JASTA BUTTERFLY-VALVE ø350 BE02 N/A JASTA GD-6 LB DN-350 No 39.5 kg
28 2 AUMA ACTUATOR SG05.1-22 BE02 N/A SG05.1-22 No %% 40.0 kg
29 2 Washer A 10.5 N/A DIN 125 - A 10.5 - St-Galv. St-Galv. 0.004 kg
30 32 Washer A 21 N/A DIN 125 - A 21 - A4 A4 0.017 kg
31 2 Spring Washer A 10 DIN 127 - A 10 - St-Galv. St-Galv. 0.003 kg
32 48 Spring Washer A 12 DIN 127 - A 12 - A4 A4 0.004 kg
33 4 Spring Washer A 12 DIN 127 - A 12 - St-Galv. St-Galv. 0.004 kg
34 32 Spring Washer A 20 DIN 127 - A 20 - A4 A4 0.016 kg
35 48 Washer 13 DIN 9021 - 13 - A4 A4 0.022 kg
36 32 Hex-Head Bolt M20 100 DIN 931-1 - M20 x 100 - A4 A4 0.315 kg
37 2 Hex-Head Bolt M10 22 DIN 933 - M10 x 22 - 8.8 Galv. 8.8 Galv. 0.025 kg
38 4 Hex-Head Bolt M12 20 DIN 933 - M12 x 20 - 8.8 Galv. 8.8 Galv. 0.035 kg
39 2 Hex Nut M10 DIN 934 - M10 - 8 Galv. 8 Galv. 0.012 kg
40 48 Hex Nut M12 N/A DIN 934 - M12 x 1 A4 0.017 kg
41 32 Hex Nut M20 DIN 934 - M20 - A4 A4 0.065 kg

A FIRST ISSUE C.L. H.J. RMuller 21-Mar-13

REV: AMENDMENT: DRAWN: CHECKED: APPROVED: APPRV'D DATE:
This document is property of BRADEN-EUROPE B.V. and if and in sofar
as othewise agreed in writing. It is put at the receivers disposal without BRADEN-EUROPE B.V.
consideration other than the receivers agreement that it shall not be copied, BRADEN
reproduced, lent or disposed of directly or indirectly nor used for any purpose Grasbroekerweg 114
other than that for which it is specifically furnished and that it is to be returned 6412 BH Heerlen
to BRADEN-EUROPE B.V. on demand together with copies made. The Netherlands

CLIENT: GENERAL ELECTRIC Title: SEAL AIR ARRANGEMENT

TOLERANCES: DIN 7168-g (T1) & DIN ISO 13920 Part Number : 11068G-A001-A002-000

EUROPEAN PROJECTION WELDINGS ACCORDING TO DIN EN ISO 22553

SEAL AIR ARRANGEMENT x x SHEET No: 1 OF 3

N/A x N/A FILE NAME: SIZE: REV:

SCALE: 1: 20 11068G-A001-A002-000.dwg A1 A
C:\Vault\Projects\11\110\11068\11068G\_Dwg\11068G-A001-A002-000.dwg
Tab 6
DWG Number 411D1010 Rev - Released 9/26/2013 Page 1 of 2

8 7 6 5 4 3 2 1
REVISION GE ALTERATION
LETTER NOTICE NUMBER

84.00
[2133.60]
41.54 O.A.L.
[1055.06]
41.28 C.O.G.
[1048.47] 13.00
28.00 DRYER S [330.20]
[711.20] PANEL
AP-3 11.00 *
26.00 [279.40]
D [660.40] D

JACK STUD, TYP.

AP-4 * DENOTES 82.00
CUSTOMER ELECTRICAL [2082.80]

[152.40]
CONNECTION

6.00
ANCHORING, TYP.
AP-1 & AP-2

& 1.00
[133.35]

[25.40]
5.25

JACK BOLT

PANEL
[38.10]
ANCHORING, TYP.

1.50
& CONTROL PANEL
A2 JACK BOLT (JB297)

A1

12.00 *
[304.80]
17.00 *
[431.80]

[805.57]
31.72

COG

ANCHORING, TYP.
JACK STUD, TYP.
[1219.20]

[1320.80]
[1524.00]

52.00
48.00
60.00

OAW

Z
Y

X
FRONT

C C

B1

ANCHORING, TYP.
B2

ANCHORING VIEW

[101.60]
4.00
PLAN VIEW SCALE 1" = 1'-0"
SCALE 1" = 1'-0"

0.00
[0.00]
CONNECTIONS FLUSH
A
WITH EDGE

ENDOR SUPPLIED - GE NOT TO REVISE. THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER AND GE REVISION LEVEL.
& GROUNDING LUG
AP-3 & AP-4
[101.60]
4.00
2.04
[51.82]

1.04
[26.42]

B 0.75 B
DETAIL B [19.05]
AP-3 & AP-4
SCALE 4" = 1'-0"
0.38
[9.53]
TYP. LIFTING TAB
4.00 SET BACK
[101.60] R0
.2
GROUNDING LUG [7.2 8
4]

P1
.0
[25.4 0
90.38 .

[72.83]
[2295.58]

2.87
0]
OAH

[25.40]
R0

1.00
[12 .50
.70
]
[1612.90]
63.50

AP-2

[1136.65]

LIFTING TAB DETAIL VIEW

44.75

AP-1

[1060.45]
PANEL
41.75

SCALE 10" = 1'-0"

(1/2" [12.7] THK.)
[885.59]
C.O.G.
34.87

5/8" [152.87]
JACK STUD
TYP, (4) PLACES
Table
CONN SIZE TYPE DESCRIPTION MATERIAL
B 5/8" [152.87]
AP - 1
AP - 2
1.50 [38]
1.50 [38]
ANSI 300# RF FLANGE
ANSI 150 RF FLANGE
AIR INLET
AIR OUTLET
304 SS
CS
A DETAIL A ANCHORING HOLE
TYP, (4) PLACES
AP - 3 0.25 [6.4] TUBING, PLAIN END COALESCER DRAIN 304 SS A
SCALE 3" = 1'-0" AP - 4 0.50 [12.2] PIPE, PLAIN END WATER SEPARATOR CS

GEC GLAUBER
DRAWN:
MKD 4/12/2013
GE Power Generation GENERAL ELECTRIC COMPANY
Schenectody, NY

FRONT CHECKED:

GMV 4/12/2013 EQUIPMENT CORPORATION

VENDOR SUPPLIED DRAWING
GE NOT TO REVISE GE REVISION LEVEL IS AS SHOWN ON THIS APPLIQUE.

RIGHT VIEW
THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER

SCALE 1" = 1'-0"

JOB NO.
TITLE:GENERAL ASSEMBLY LAYOUT THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE

1088760 DESC: 200 CFM APU SKID

THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.

SCALE 1" = 1'-0" 3 9/18/2013

REMOVED PO NUMBER & UPDATED GE
AMN GMV THIS DOCUMENT IS THE SOLE
PROPERTY OF GLAUBER
PROJECT: SIDDHIRIGANJ
FIRST MADE FOR: ML- 9K1WFA163-1T1 IPS 720103 MLI-A130 1 OF 2

DRAWING NUMBER EQUIPMENT CORPORATION. MFG FOR: GENERAL ELECTRIC GE SIGNATURES DATE GE DRAWING NUMBER REV
THE EXPLOITATION OR
2 7/16/2013 AS BUILT MKD GMV TRANSFER OF ANY INFORMATION SIZE DRAWING NO. REV CHECKED:

1 4/12/2013 INITIAL REVIEW MKD GMV HERIN IS NOT PERMITTED. ANY

AND ALL INFORMATION CONTAINED D 1088760-201 3
REV DATE DESCRIPTION DRAWN CHECKED IN THIS DOCUMENT MAY NOT BE
RELEASED WITHOUT THE CONSENT
SCALE: ISSUED: 411D1010
REVISION HISTORY OF GLAUBER EQUIPMENT
CORPORATION.
NOTED AS BUILT 1 OF 2
8 7 6 5 4 3 2 1

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 411D1010 Rev - Released 9/26/2013 Page 2 of 2

8 7 6 5 4 3 2 1

NOTES:
1. MATERIAL OF CONSTRUCTION TO BE STRUCTURAL STEEL, ASTM A36. HEAT EXCHANGER

2. DECKING SHALL BE 3/8" [9.5mm] ASTM A36 CARBON STEEL PLATE.

3. BASES TO BE CLEANED AND PAINTED: CLEAN PER SSPS-6 COMMERCIAL SANDBLAST APPLY PRIMER
D PER GE SPECIFICATION D
4. ALL STRUCTURAL WELDS PER AWS D1.1
5. ALL PIPING WELDS PER ASME B31.3.
6. DIMENSIONS ARE ±1/4". [6.35mm]
7. APPROXIMATE SKID WEIGHT 3250 LBS.[1474 kg]
8. PLANT DESIGNER / PLANT INSTALLER SHALL PROVIDE ALL NUTS, BOLTS, WASHERS AND FOUNDATION 34AD-1
BOLTS LOCATED BY (AIR DRYER)

MOUNTING HOLE DIMENSIONS SHOWN IN THIS DRAWING BOLTS SHALL BE EMBEDDED IN THE
FOUNDATION TO RESIST A
FULL FORCE EQUAL TO THE ALLOWABLE BOLT STRENGTH.
9. PLANT DESIGNER / PLANT INSTALLER ELECTRICAL CONNECTIONS FOR JB297 AS SHOWN IN THIS DWG
TO BE DRILLED
IN FIELD BY INSTALLER.
10. ALL DIMENSIONS IN INCHES, UNLESS OTHERWISE SPECIFIED, DIMENSIONS IN [ ] ARE IN MM.
11. THE TOTAL RESULTANT FORCE AND TOTAL RESULTANT MOMENT
AP-2

IMPOSED ON ANY CONNECTION MUST NOT EXCEED THE FOLLOWING:

F=(100) X (D) M=(200) X (D) WHERE F=RESULTANT FORCE IN POUNDS.
M=RESULTANT MOMENT IN FT-LBS D=PIPE SIZE OF CONNECTION IN INCHES
UP TO 8 INCHES IN DIAMETER. FOR SIZE GREATER THAN 8 INCHES IN DIAMETER
USE A VALUE OF (D) EQUAL TO (16+N.P.S.)/3 INCHES. OR
F=17.79XD(N)
M=10.85XD(N-M)
WHERE F=RESULTANT FORCE IN NEWTON
M=RESULTANT MOMENT IN NEWTON METER
D=NOMINAL BORE UP TO 200NB
FOR SIZE > 200NB
D=[400+D/3] AP-1

12. MAINTENANCE CLEARANCE IS 2 FEET [609.6mm] UNLESS OTHERWISE SPECIFIED.

C 13. JUNCTION BOX CLEARANCE IS 3 FEET [914.4mm] IN FRONT OF PANEL. C
14. CENTER OF GRAVITY COORDINATES FROM GEOMETRIC CENTER AND BOTTOM OF SKID. CONTROL PANEL
15. FLANGE BOLT HOLES SHALL STRADDLE CENTERS. (JB297)

PLANT DESIGNER AND/OR PLANT INSTALLER INTERFACE TABLE

CONN. SIZE TYPE DESCRIPTION MATERIAL

AP-1 1.50 [38.1] ANSI 300# RF FLANGE AIR INLET 316SS

AP-2 1.50 [38.1] ANSI 150 RF FLANGE AIR OUTLET 304SS

AP-3 0.25 [6.4] TUBING, PLAIN END COALESCER DRAIN 316SS

AP-4 0.50 [12.7] TUBING, PLAIN END WATER SEPERATOR 316SS

B B

AP-4

AP-3

GEC GLAUBER
DRAWN:
MKD 4/12/2013
A CHECKED: A
REAR ISOMETRIC VIEW GMV 4/12/2013 EQUIPMENT CORPORATION
SCALE 2" = 1'-0" JOB NO.
TITLE:GENERAL ASSEMBLY LAYOUT
1088760 DESC: 200 CFM APU SKID
THIS DOCUMENT IS THE SOLE PROJECT: SIDDHIRIGANJ
PROPERTY OF GLAUBER
EQUIPMENT CORPORATION. MFG FOR: GENERAL ELECTRIC
THE EXPLOITATION OR
TRANSFER OF ANY INFORMATION SIZE DRAWING NO. REV
HERIN IS NOT PERMITTED. ANY
AND ALL INFORMATION CONTAINED D 1088760-201 3
REMOVED PO NUMBER & UPDATED GE IN THIS DOCUMENT MAY NOT BE
SCALE:
3 9/18/2013 AMN GMV RELEASED WITHOUT THE CONSENT
DRAWING NUMBER OF GLAUBER EQUIPMENT
CORPORATION.
NOTED AS BUILT REV
2 7/16/2013 AS BUILT MKD GMV GE DRAWING NUMBER REV
1 4/12/2013 INITIAL REVIEW MKD GMV
REV DATE DESCRIPTION DRAWN CHECKED
411D1010
REVISION HISTORY 2 OF 2

8 7 6 5 4 3 2 1

GE Proprietary Information - Class II (Internal) US EAR - NLR

WG Number 143E2289 Rev C Released 4/20/2012

# ,    + ( !


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566789

GE Proprietary Information - Class II (Internal)

US EAR - NLR
g
GEK 116681
July 2010

GE Energy

Air Processing Unit

(7EA, 7FA, 7FB, 9FA, 9FB, Self-cleaning filters only)

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 116681 Air Processing Unit

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Air Processing Unit GEK 116681

TABLE OF CONTENTS

I. SYSTEM INTRODUCTION ........................................................................................................ 4

II. SYSTEM OVERVIEW.................................................................................................................. 4

III. SYSTEM COMPONENT DESCRIPTION ................................................................................. 4

IV. SYSTEM OPERATION ................................................................................................................ 5

V. SYSTEM TECHNICAL DATA ................................................................................................... 5

VI. SYSTEM LEVEL MAINTENANCE INSTRUCTION.............................................................. 5

VII. SYSTEM LEVEL TROUBLE SHOOTING INSTRUCTION.................................................. 5

VIII. ADDITIONAL REQUIREMENTS............................................................................................ 5

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 116681 Air Processing Unit

I. SYSTEM INTRODUCTION

The Air Processing Unit (APU) provides the air supply for pulsing the self-cleaning filters by using ex-
tracted air from the Gas Turbine compressor. The operational system of the APU is an integrated series of
processes within one module. The intent of the system is to provide cool dry air at appropriate pressure
for pulse cleaning of self-cleaning filters in the Inlet Filter House. The volume of airflow depends on the
number of filters cleaned, which in turn depends on the size of filter house and varies along the frame size
of the gas turbine.

II. SYSTEM OVERVIEW

The initial process is to cool the incoming hot air from the Gas Turbine compressor by passing the extracted
air through a finned tube air-to-air heat exchanger assembly. The condensate that drops out in the heat ex-
changer and any water slugs from the piping upstream of the APU is removed using a water separator with
an automatic drain trap. The air passes through a standard diaphragm type, adjustable pressure regulator
valve, which reduces system pressure to desired levels. The final process is to remove any particulates, oil
mist and condensate in the air using a coalescing filter and a heatless air dryer configuration.

The condition of the extracted air, or bleed air, from the Gas Turbine compressor varies depending on the
Gas Turbine modes of operation. The bleed airflow demand to the APU inlet may vary depending on the
downstream end-use demands. Downstream demand will be a maximum when the filters are under pulsing
action and can be close to zero when the filters are not pulsing. Since filter pulsing is based on a matter
of time and pressure drop built-up in the filter house, some sites may have filter pulsation once a day (for
base load operations) or once a week (for peaking units) for an hour or so. This cycle may vary depending
on site conditions and Gas Turbine modes of operation.

NOTE

Equipment included in this contract is shown on the project specific schematic.

The system description may describe or refer to optional equipment not provided
on this contract.

III. SYSTEM COMPONENT DESCRIPTION

The system consists of a pre-piped skid module which includes an air-cooled heat exchanger with a cooling
fan (88AD-1), a pressure regulator (VPR67-1), a coalescing filter, heatless desiccant type dryer (34AD-1),
and a condensate drain. Instrumentation includes temperature gauges, pressure gauges and a low-pressure
alarm switch. There is a temperature controller coupled with a temperature sensor (preferably a RTD) to
control the function of the fan motor (88AD-1) and isolation solenoid valve (20AP-1). A control system is
provided with the air dryer. The air dryer (34AD-1) is a two-chamber arrangement with one chamber on
online drying mode while the other is on offline desiccant regeneration mode. The control system sequences
the solenoid valve (20AP-1), which supplies compressed air to pneumatic diaphragm valves on the air dryer
(34AD-1), which in turn control process airflow between drying and regenerating chambers. Process air
and condensate piping located after the heat exchanger are insulated & if required, heat traced.

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Air Processing Unit GEK 116681

IV. SYSTEM OPERATION

The compressed air is extracted from the compressor discharge and is fed to the Air Processing Unit inlet
purchaser connection AP-1. The pressure and temperature conditions depend on the frame size of the Gas
Turbine. The heat exchanger configuration including fan motor (88AD-1) cools the hot air to a temperature
less than 145 °F. This may cause some condensation to occur & the water separator downstream of the
arrangement is intended to remove the water from the air stream. The temperature controller APU-LIC-1
(provided with integrated temperature sensor) measures the compressed air temperature and sends signals
to the 88AD-1-fan motor as well as to the solenoid isolation valve 20AP-1. When the temperature reaches
110 °F (43 °C) increasing the controller sends a signal to start the motor 88AD-1. When the temperature
goes above 145°F (63°C) the controller sends a signal to close the isolation valve 20AP-1. For sites which
require heat tracing there will be instrumentation to sense temperature & heating cables to automatically
control the pipe temperature. In case of self-heat regulation, the sensing action is built-in.

The compressed air then reaches the pressure-regulating valve (VPR67-1), which automatically regulates
the flow for the set outlet pressure. This reduction in pressure also calls for a water drain mechanism
downstream either separate or integral with the dryer system. The two heatless dryers (34AD-1) are 2 X
100%. While one is in operation the other will be on regenerative mode. This regenerative mode uses
15% of the total airflow. The outcome of the process is air with pressure and temperature as required for
the pulse cleaning of the Gas Turbine inlet air filters. The outlet air exits the APU at purchaser connection
AP-2. The two drain lines from the APU exit the skid at purchaser connections AP-3 and AP-4.

V. SYSTEM TECHNICAL DATA

Refer to site-specific drawings for flow, pressure and temperature design conditions and piping purchaser
connection sizes and flange ratings.

VI. SYSTEM LEVEL MAINTENANCE INSTRUCTION

Refer Vendor document submittal, DIS 201 Operation & Maintenance manual for details.

VII. SYSTEM LEVEL TROUBLE SHOOTING INSTRUCTION

Refer Vendor document submittal, DIS 201 Operation & Maintenance manual for details.

VIII. ADDITIONAL REQUIREMENTS

If the equipment is used in a manner not specified by the manufacturer the protection of the equipment may
be impaired.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

GEK 116681 Air Processing Unit

Typical APU Electrical Requirements:

For 60 Hz units: 120 VAC for 50 Hz units: 230VAC

20Amps 20Amps
I phase I phase

CAUTION

Refer to DIS 201 for project specific instructions before operating the system.

• Disconnect power before servicing the system.

• Connection to main power supply must be made by fully qualified person only.
All connections must be made in accordance to the manufacturers instruction
and all local and national electric codes

• The system must be connected to protective earth at all times.

• Lift the systems only as per the manufacturer’s instructions and recommenda-
tions.

• Activated Alumina desiccant dust is considered a nuisance dust. Proper pre-

cautions should be taken before desiccant replacement. Refer to MSDS.

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Air Processing Unit GEK 116681

THIS PAGE INTENTIONALLY LEFT BLANK

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116681 Air Processing Unit

g
GE Energy
General Electric Company
www.gepower.com

8 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Tab 7
Inlet Bleed Heat Control System Schematic
96AP- 1,2,3
96CS-1 96CD- 1,2,3

Turbine Exhaust Flow

Inlet Airflow Compressor
Combustion

VM15-1
Manual/Motor
Operated
AT-1D 1,2,3 Isolation Valve
CT-IF-1,2
96BH-2
96BH-1
PT PT

VA20-1
Air Operated I/P
Control Valve 3

2/12/2014
g
GEK 116865
April 2011

GE Energy

Compressor Inlet Bleed Heat System

(9FA)

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
 GEK 116865 Compressor Inlet Bleed Heat System

I. GENERAL

The Compressor Inlet Bleed Heating system recirculates a fraction of the hot compressor discharge
airflow into the compressor inlet Figure 1 is a top level summary diagram of the system. The system is
used for the following three main purposes:

1. To prevent conditions necessary for the formation of ice on the first stage stator blades
2. To extend emissions compliance to lower loads by allowing exhaust temperature control to occur at
lower inlet guide vane angles.
3. To provide sufficient compressor operating margin by reducing the compressor pressure ratio and by
heating the compressor inlet air.

Gas turbine range may be restricted for cold compressor inlet temperatures in order to protect the gas
turbine compressor from exceeding its operating limit and/or inlet ice buildup. Gas turbines that operate
with the inlet guide vanes at restricted angles at low ambient temperatures are prone to inlet ice formation
and reduced compressor operating limit. With such designs, inlet heating becomes necessary to guarantee
full gas turbine operating range.

II. SYSTEM COMPONENTS

1. Manual isolation valve (VM15-1) is used to provide shutoff capability. Includes normally open limit
switch (33TH-3) that closes when the manual isolation valve is fully open.
2. Inlet Bleed Heat Control Valve assembly (VA20-1) is a electrically actuated control valve. The
following components are mounted on the control valve:

a. An inlet bleed heat quick exhauster valve (VA42-1) along with associated needle valve which is
adjustment for quick exhaust valve.

b. Trip solenoid valve (20TH-1).

c. LVDT (96TH-1) for IBH Control Valve (VA20-1) position feedback.

d. Inlet Heating Control Valve Volume Booster (VA40-1).

3. Pressure transducer (96BH-1) measures the pressure upstream and similarly pressure transducer
(96BH-2) measures the pressure downstream of the inlet bleed heat control valve (VA20-1). These
pressure transducers, along with IBH control valve position and compressor discharge temperature,
are used to compute inlet bleed heat flow.
4. Pressure Regulator (VPR41-1) which has Instrument Air I/P from Turbine Inlet air heating control
valve.
5. Electro-pneumatic transducer (65EP-3).
6. The Mark * VI VSVO Servo Board provides closed loop position control of the IBH valve.
Refer to the Inlet Air Heating schematic diagram MLI 0432.

*
Trademark of the General Electric Company.

2 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Compressor Inlet Bleed Heat System GEK 116865

III. OPERATION

For emissions turndown and compressor first stage icing prevention the amount of inlet bleed heat in
terms of percent compressor airflow is scheduled as a function of Inlet Guide Vane (IGV) angle.

GE gas turbine compressors are designed to operate below a compressor pressure ratio limit (CPRLIM)
that is a function of inlet guide vane angle (IGV) and temperature corrected rotor speed (TNHCOR).
Combinations of factors such as extreme cold ambient temperatures, low IGV angles, high combustion
reference temperature, low BTU gas fuel composition, online water wash, gas to liquid fuel transfers, and
high combustor diluent injection can cause the Mark* VIe controller to increase inlet bleed heat flow in
order to provide sufficient compressor operating margin.

The fail-safe position of the inlet bleed heat control valve (VA20-1) is the full open position. The valve
will fail open upon loss of electrical command signal to the servovalve.

The inlet bleed heat control valve (VA20-1) is tripped open by the Mark* VIe controller via the trip
solenoid (20TH-1) by means of electrical actuation. The IBH control valve is tripped open given one of
the following conditions:

1. The valve position feedback signal fails to follow command within a specified tolerance for greater
than a specified length of time.
2. The compressor pressure ratio (CPR) exceeds a maximum allowable limit (CPRLIM) for greater
than a specified length of time.
3. Ambient pressure (AFPAP) is above a high limit.

The two alarms associated with the inlet bleed heat system are ‘IBH CONTROL VALVE NOT
TRACKING’ and ‘IBH PRESSURE TRANSDUCER FAULT’.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 3

GEK 116865 Compressor Inlet Bleed Heat System

Figure 1. Top Level Summary Diagram

4 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Compressor Inlet Bleed Heat System GEK 116865

THIS PAGE INTENTIONALLY LEFT BLANK

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 5

GEK 116865 Compressor Inlet Bleed Heat System

g GE Energy
General Electric Company
www.gepower.com

6 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4571 Rev - Released 10/25/2012 Page 1 of 1

SIZE DWG. NO. SH. REV.

E 1 -
REVISIONS
THIS DOCUMENT SHALL BE
NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION ARE THE SAME REVISION
INCLUDED IN MLI 0438 APPLY. LEVEL AS INDICATED.
3. THE TERM “OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT
DESIGNER AND/OR INSTALLER.
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH "PC" INDICATE
CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH "PC" ARE
GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
5. LOCATE VM15-1 AND VA20-1 AS CLOSE POSSIBLE TO THE GAS TURBINE BASE
ENCLOSURE.
6. LOCATE THE STATIC PRESSURE TAP FOR 96BH-1 AT A MAXIMUM OF 3.0 FT
[0.91 M] UPSTREAM OF VA20-1.
7. LOCATE THE STATIC PRESSURE TAP FOR 96BH-2 AT LEAST 8-10 PIPE
DIAMETERS DOWNSTREAM OF VA20-1. PIPING BETWEEN VA20-1 AND 96BH-2
MUST BE A STRAIGHT RUN.
8. REFER TO FIELD INTERCONNECTING PIPING INSTRUCTION (MLI A187) FOR
FUNCTIONAL DESCRIPTION OF PIPING DESIGN REQUIREMENTS.
9. INLET AIR HEATING PIPING BY OTHERS.
10. NEEDLE VALVE IS ADJUSTMENT FOR QUICK EXHAUST VALVE VA42-1, THIS
VALVE IS FACTORY SET.
11. FOR MOUNTING INSTRUCTIONS REFER TO MLI 0302 (PURCHASER MOUNTED
DEVICES).

VPR41-1 VA40-1
PC VA42-1
IH7
INSTRUMENT AIR
“BY OTHERS”

65EP-3
20TH-1

SEE NOTE 10

PT PT
96BH-1 96BH-2

ZS NC NC
33TH-3 NO ZT NO
PC 96TH-1
SEE NOTE 8 TURBINE PRESSURE TRANSDUCER ARRANGEMENT 557T TURBINE PRESSURE TRANSDUCER ARRANGEMENT 557T
IH3
FROM MLI 0417 TO MLI 0471
CLG & SLG, “CA16" INLET & EXHAUST, “IE20”
NO PC SEE NOTE 6 PC FO PC SEE NOTE 7
A187 VM15-1 IH4 IH1 VA20-1 IH2

INLET HEATING CONTROL ARRANGEMENT A037

SEE NOTES 1,5, 8 & 11

INLET HEATING CONTROL ARRANGEMENT A037

SEE NOTES 1, 5, & 11

1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671

IT. NOMENCLATURE IDENT
LIST OF COMPLEMENTARY DOCUMENTS
GE CLASS II (INTERNAL NON-CRITICAL)
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY
© COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. DIMENSIONS ARE IN INCHES
DRAWN
CANDELARIA, ARNOLD 12-10-15
g GE Energy GAS TURBINE
ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE TOLERANCES ON CHECKED
ENERGY GAS TURBINE PROPRIETARY TECHNICAL INFORMATION THAT 2 PL DECIMALS ± SEE PLM 12-10-15
BELONGS TO THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA), LLC 3 PL DECIMALS ± ENGRG
LAMAR, CARL 12-10-15
AND/OR THEIR AFFILIATES, WHICH HAS BEEN PROVIDED SOLELY FOR
THE EXPRESS REASON OF RESTRICTED PRIVATE USE. ALL PERSONS,
ANGLES ±
FRACTIONS ± ISSUED
SEE PLM 12-10-15
DIAG, SCHEM PP-INLET AIR HTG
FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL BE
DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED QUALITY

TO MAKE NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER

FOR ANY, OR ALL SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED FIRST MADE FOR: ML-9K1WFA163-1 0432
THIRD ANGLE PROJECTION IN WRITING BY THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA),
SIZE CAGE CODE DWG NO
LLC AND/OR ITS AFFILIATES.

DISTR
SIM TO:

TO
NONE SCALE SHEET 1 of 1

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T2206 Rev A Released 6/27/2013 Page 1 of 3

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T2206 Rev A Released 6/27/2013 Page 2 of 3

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T2206 Rev A Released 6/27/2013 Page 3 of 3

GE Proprietary Information - Class II (Internal) US EAR - NLR

Tab 8
 GEK 111323
August 2005

GE Energy

Performance Monitor

These instructions do not purport to cover all details or variations in equipment nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance. Should
further information be desired or should particular problems arise which are not covered sufficiently for
the purchaser's purposes the matter should be referred to the GE Company.
© 2005 General Electric Company
Performance Monitor GEK 111323

Results of the last successful performance run and baseline run may be viewed directly from the pro-
gram.

B. Relative Data Presented

The performance monitor compares current performance against a baseline run which must have been
previously made for each turbine in the plant. Results are given in percent deviation from the baseline
run. When a baseline run is completed, it is saved, and future performance runs will be compared to
this base.

C. Interpretation of Results

The programs used to calculate the deviations are complex, making use of proprietary information
about the internal design of specific General Electric gas turbines. Over the range of operation, the
calculations are generally accurate to 1% with occasional instances of 2% error where operation is far
from design point.

Program Output gives the deviations from the baseline run for the following parameters:

1. Heat Rate

2. Compressor flow

3. Inlet drop

4. Exhaust drop

5. Compressor efficiency

6. Turbine efficiency

7. Effective nozzle area

8. Expected generator output

D. Expected Generator Output-Power Balance

Expected Generator Output (power balance) is calculated by two different methods from sensor data
and directly compared; the deviation of this power balance is presented. The power balance deviation
is a measure of the validity and accuracy of the sensor data used in the calculations. High Expected
Generator Output (power balance) deviation is often a result of miscalibrated sensors. If a problem
exists or is suspected, the operator can apply some commonsense procedures to obtain additional in-
formation. Making the changes one at a time will show the effect of the change on calculation output.
In this way the transducers, which need recalibration, can be determined. Inputs with a significant
influence on Expected Generator Output (power balance) deviation include inlet temperature, exhaust
temperature, barometric pressure, bell mouth pressure drop, output power, fuel flow, lower heating
value, and injection steam flows.

The Expected Generator Output (power balance) should be 5% or less.

3
Performance Monitor GEK 111323

IV. EXPECTED PERFORMANCE

Using reference data we can calculate the expected power at whatever the current ambient temperature is
using the formula:

Where,

PEXP= Expected Power (Expected Performance)

PREF= Reference power (ISO day)
CT = Inlet temperature
CP= ambient temperature
CRH= % relative humidity
CINDP= inlet pressure loss
COUTDP= exhaust pressure loss

V. EMAPVIEW

EmapView provides an interface to the EfficencyMapTM inputs and calculated results. The EMapView
program is the Windows display tool that allows the operator to view the current snapshot of gas turbine data
online and compare Measured, Heat Balance, Expected and Corrected To Reference values. The reports
within EMapView present the EfficencyMapTM results in a format that allows you to evaluate the plant’s
current performance.

The date and time in EMapView’s status bar indicates the starting time of the last complete calculation
cycle. EMapView periodically checks the EfficencyMapTM data files to determine if a newer snapshot is
available. When a new set is available, EMapView automatically refreshes all open reports.

The performance report lists heat balance and expected data and the percent deviation between these two
values. The most important performance indicators are included within this report. By sorting on the
percent deviation, you can quickly identify potential problem areas in plant performance.

For operating instructions refer to: “User Guide for EfficiencyMapTM Performance Monitoring Sys-
tem On GE Turbine Control System HMI”

5
GEK 111323 Performance Monitor

GE Energy
General Electric Company
www.gepower.com

6
WG Number 146E4483 Rev B Released 2/24/2012

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GE Proprietary Information - Class II (Internal)

US EAR - NLR
Tab 9
AkerSolutions
PLAN VIEW

AkerSolutions
FRONT VIEW

AkerSolutions
REAR VIEW

AkerSolutions
LEFT SIDE VIEW RIGHT SIDE VIEW

AkerSolutions
AkerSolutions
 Control Valve Configuration- Simplified
* System Control Valves
• SRV (Gas)
FA Oil Systems-
LVDT’s
* •
•
GCV1 (Gas)
GCV2 (Gas) Gas Fuel -
• GCV3 (Gas)
Dump
Valve
•
•
GCV4 (Gas)
IGV (Air) Simplified Diagram
Servo
Valve Filter

Hydraulic System
TG
HO Control Oil
Pumps GT 1 Gen CE
VPR4
20QB %HDULQJV
Lift Oil
GT2 Gen TE

Trip
Oil To
VPR2 ATM
* Trip Valves Seal Oil
•20FG (Gas)
•20TV (VIGV) Filter BDET H2 Panel
LO
Vapor H2
Cooler Mist Gas
Eliminator
SDET

LO ELO SO
(2) Lube Oil Return
Pumps

Lube Oil Tank

5HY3: 
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2
 GEK 111768

g
August 2007

GE Energy

Lubrication System

These instructions do not purport to cover all details or variations in equipment nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further
information be desired or should particular problems arise which are not covered sufficiently for the purchaser's
purposes the matter should be referred to the GE Company.

© 2007 General Electric Company

GEK 111768 Lubrication System

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2
 Lubrication System GEK 111768

TABLE OF CONTENTS

I. GENERAL ..................................................................................................................................................... 4
II. FUNCTIONAL DESCRIPTION.................................................................................................................. 5
A. Lubricant Reservoir and Piping................................................................................................................. 5
B. Standby Immersion Heaters ...................................................................................................................... 6
C. Pressure Protection Devices ...................................................................................................................... 6
D. Heat Exchanger and Filters ....................................................................................................................... 7
E. Seal Oil...................................................................................................................................................... 7
III. OPTIONAL DEVICES ................................................................................................................................. 7
A. Pressure Transmitters ................................................................................................................................ 7
B. Lube Oil Conditioner ................................................................................................................................ 8

3
GEK 111768 Lubrication System

I. GENERAL

The lubricating and hydraulic oil requirements for the 9FA gas turbine power plant are furnished by a
separate, enclosed, forced-feed lubrication module. This lubrication module, complete with tank, pumps,
coolers, filters, valves and various control and protection devices, furnishes oil to the gas turbine
bearings, generator bearings (absorbing the heat rejection load), starting means, load gear and on dual
fuel units the atomizing air/purge compressors. This module is also used to supply oil for the lift oil
system, trip oil system and the hydrogen seals on the generator. Additionally, a portion of the pressurized
fluid is diverted and filtered again for use by hydraulic control devices as control fluid.

Refer to “Lubricating Oil Recommendations for Gas Turbines with Bearing Ambients above 500°F
(260°C)” in the FLUID SPECIFICATIONS section of this manual for the lubricating oil requirements.

The lubrication system is designed to supply filtered lubricant at the proper temperature and pressure for
operation of the turbine and its associated equipment. Refer to the Lube Oil Schematic Piping Diagram in
this section. Major system components include:

1. Lubricant oil reservoir which serves as a base for the accessory module.
2. Two centrifugal pumps (PQ1-1 and PQ1-2) each driven by an AC electrical motor (88QA-1 and
88QA- 2). Each AC motor includes a motor space heater (23QA-1 and -2) to prevent condensation
in the motor.
3. Emergency oil pump (PQ2-1) with DC motor (88QE-1).
4. Main Seal oil pump (PQ3-1) driven by AC motor (88QS-1). AC motor includes motor space heater
(23QS-1).
5. Emergency seal oil pump driven by DC motor (88ES-1). Note, in most instances PQ3-1 is a
“piggyback” AC/DC motor driving one pump. If the Customer has opted to purchase separate AC
and DC seal oil pumps, the separate DC pump will be named PQ3-2.
6. Dual lubricating oil heat exchangers in parallel (LOHX-1 and LOHX-2).
7. Two full flow lubricating oil filters in parallel (LF3-1 and LF3-2).
8. Bearing header pressure regulator (VPR2-1).
9. Mist eliminator (LF3-3) with redundant fan/motor (88QV-1A and 88QV-1B) and motor space
heaters (23QV-2A and 23QV-2B).
10. Pressure Protection Switches (63QA-1A, 63QA-1B, 63QE-1, 63QT-2A and 63QT-2B. On Dual fuel
units with single atomizing air compressor, pressure switch (63QA-3) is provided. On Dual fuel
units with dual atomizing air compressors, two pressure switches (63QA-3 & 63QA-4) are provided.
11. Tank temperature thermocouples (LT-OT-3, LT-OT-4) for pump start permissive and immersion
heater control.
12. Lube oil header thermocouples (LT-TH-1, 2, 3).
13. Lube oil drain thermocouples (LT-B1D-1, LT-B2D-1, LT-G1D-A/B and LT-G2D-A/B).Note, “A/B”
indicates dual element thermocouples.

The lube oil is circulated by a redundant set of AC pumps. A DC pump is provided in case AC power to
the site is interrupted. These pumps are the first of the auxiliary equipment to be energized during a
startup sequence. Following shutdown of the unit, these pumps continue to run throughout the extensive
cooldown period and are the last of the auxiliary equipment to be stopped. The lube oil system is self-

4
Lubrication System GEK 111768

contained. After lubricating and removing heat from the rotating equipment, oil is returned to the lube oil
tank. It is cooled by oil-to-water heat exchangers as it is pumped from the tank and re-circulated. Various
sensing devices are included in the design to ensure adequate oil level in the tank, oil pressure, and oil
temperature.

Oil tank temperature is indicated by a thermometer on the side of the tank. Thermocouples LT-TH-1, LT-
TH-2 and LT-TH-3 connected to the control panel indicate lube oil temperature in the bearing header.
Thermocouples in the bearing drains are also wired to the turbine control panel for monitoring. A bearing
header oil sampling port is located upstream of VPR2-1.

For turbine starting, a maximum oil viscosity of 800 SUS (173 centistokes) is specified for reliable
operation of the control system and for bearing lubrication. Thermocouples LT-OT-3 and LT-OT-4
prevent turbine startup if the temperature of the lubricant decreases to a point where oil viscosity exceeds
800 SUS (173 centistokes).

II. FUNCTIONAL DESCRIPTION

A. Lubricant Reservoir and Piping
The oil reservoir is integral with the module. The interior of the tank is coated with an oil resistant
protective coating. The top of the tank is the base on which components such as the pumps, and heat
exchangers are mounted.

Under normal operating conditions oil is provided to the system by one of two main AC motor driven
centrifugal pumps (PQ1-1 and PQ1-2). The selection of lead and lag pumps is made by the operator
through the turbine control system prior to startup. By alternating the lead/lag pump selection, the
operating hours can be equalized. Each AC motor includes a motor space heater (23QA-1 and -2) to
prevent condensation in the motor. All pumps have a check valve on the discharge line so that oil
does not flow into the tank through a pump, which is not in service. Two pressure switches (63QA-
1A and -1B) are mounted in the common header just downstream of the main pumps to ensure proper
pump operation. If either of these senses low pressure, an alarm is sounded and the lag pump is
automatically started. If this occurs, the operator must manually shut off one pump and check that
system pressure is stable.

The oil is first pumped through one of the two parallel heat exchangers (LOHX-1 and LOHX-2).
Each is designed to maintain the oil at the proper bearing header temperature. The maximum
allowable bearing header temperature under normal operating conditions is 160°F (71.1°C). The oil
then flows through one of the two full flow parallel filters (LF3-1 and LF3-2). A three-way transfer
valve controls selection of which set of heat exchanger/filter is in use. The lubricant oil filters have
removable filter elements. A differential pressure gauge provides visual indication of the dP over the
filter. Pressure switches (63QQ-21, -22) provide a high differential pressure alarm signal across each
filter. Filter elements should be replaced near or at the alarm set point.

Taps (OL-11), (OH-1) and (OLT-1), which are located downstream of the filters, supply lube oil to
the generator bearing seals, hydraulic/lift oil system and trip oil system respectively. Pressure
regulating valve (VPR2-1) then controls the oil pressure to the turbine and generator bearings and the
turning gear.

The system is ventilated through a mist eliminator mounted on top of the lube oil reservoir. A slight
negative pressure is maintained in the system by redundant motor driven fans (88QV-1A; FB1-1 and
88QV- 1B; FB2-1) pulling air through the mist eliminator. This negative pressure draws sealing air
through the gas turbine bearing seals. Each AC motor includes a motor space heater (23QV-2A and

5
GEK 111768 Lubrication System

23QV-2B) to prevent condensation in the motor. The motor driven fans have no DC backup motors
and are not required to run in the emergency situation, when the DC pumps has taken over. The fans
are set up to run in a lead/lag configuration and are designed to run one at a time. The selection of
lead and lag fans is made by the operator through the turbine control system prior to startup. The lag
fan takes over whenever the lead fan has failed to run, has been overloaded or if there is insufficient
vacuum in the lube oil reservoir. If the lag fan is started automatically by the control system due to
insufficient tank vacuum level, the lead fan will be automatically shut off. Pressure switch (63QV-1)
provides a low differential pressure alarm signal when there is insufficient vacuum in the lube oil
reservoir. A regulating valve is downstream of each fan, and is adjusted to regulate tank vacuum
level.

A level alarm device (float operated) is mounted on the top or side of the lube reservoir. The float
mechanism operates level switches (71QH-1, 71QL-1 and 71QL-2). The switches are connected into
the alarm circuit of the turbine control panel to initiate an alarm if the liquid level rises above, or falls
below the levels shown on the Schematic Piping Diagram. The oil level is visually indicated by a
gauge (QH-1) mounted on the top or side of the tank. An oil drain connection is located on the side of
the accessory module to drain the reservoir.

B. Standby Immersion Heaters

During standby periods, the oil is maintained at a viscosity proper for turbine start-up by immersion
heaters (23QT-1, -2 and 3) installed in the oil reservoir. Thermocouples LT-OT-3 and LT-OT-4
control the heaters and maintain fluid temperature to achieve allowable viscosity. If the heaters fail to
function and the oil reservoir temperature drops below the point where oil viscosity exceeds 800
SUS, thermocouples LT-OT-3 and LT-OT-4 will initiate a low oil temperature alarm and will prevent
a turbine startup. While running, lube oil header thermocouples (LT-TH-1, 2, 3) constantly monitor
the header oil temperature. These thermocouples are hardware voted to the median temperature and
are wired back to the control panel, and compared to alarm and trip settings. Thermocouples LT-OT-
1A, 1B and 1C are provided to monitor heater temperature and de-energize when required.

C. Pressure Protection Devices

Two pressure switches (63QA-1A and -1B) mounted on the main pump discharge header sense lube
oil pressure. If either of these senses low lubricant oil pressure, an alarm is sounded and the lag pump
is automatically started. Pressure switches 63QT-2A and -2B in combination with alarm switches
63QA-1A and 63QA-1B, trip the unit and start the emergency DC motor-driven pump (88QE-1)
when they sense low pressure. This will occur if AC power is lost. For a trip, one of the two 63QT
switches and one of the two 63QA switches must signal. This voting logic prevents a trip due to a
false signal. The DC Emergency Pump is designed to provide adequate lube oil circulation for coast
down following a trip. Once the unit is at rest, the DC pump should only operate a few minutes per
hour, in order to remove heat, but conserve battery life. If the bearing metal temperature is above
250F, the DC pump is run continuously. The emergency pump is sized to clear the trip pressure
switches (63QT-2A, - 2B), but will not clear the alarm pressure level (63QA-1A, -1B). On dual fuel
units with a single atomizing air compressor a pressure switch (63QA-3) is provided at the oil supply
to the air compressor gearbox. Two pressure switches (63QA-3 and 4) are provided on dual fuel units
with two atomizing air compressors. These pressure switches will alarm if low pressure is sensed at
those points but they will not start the lag pump.

The operation of the 63QA and 63QT switches can be verified by shutting off the normally open
valve between the switch and the oil system. When the normally closed valve to the oil drain is
opened, the oil in the switch lines will drain, the proper warning signal should annunciate and proper
lag/emergency pump start-up should occur.

6
Lubrication System GEK 111768

D. Heat Exchanger and Filters

The lubricant oil heat exchangers (LOHX-1 and LOHX-2) connect to the parallel lubricant filters
(LF3-1 and LF3-2). This design is provided so that filters not in service can be changed (or heat
exchangers cleaned) without taking the turbine out of service.

Filter housings and heat exchangers are self-venting. A sight glass is located in the vent line from the
filter and heat exchanger. When the heat exchanger and filter housing are full, oil will be visible in
this sight glass.

By means of the manually-operated three-way transfer valve, one filter can be put into service as the
second is taken out, without interrupting the oil flow to the main lube oil header. The transfer of
operation from one filter to the other should be accomplished as follows:

1. Open the filler valve and fill the standby filter until a solid oil flow can be seen in the flow sight
in the filter vent pipe. This will indicate a “filled” condition.

2. Operate the transfer valve to bring the standby filter into service.

3. Close the filler valve.

This procedure simultaneously brings the reserve heat exchanger into service.

NOTE

Only one heat exchanger is intended to be in service at one time. After transfer, the
operator must verify that the cooling water isolation butterfly valves to/from the
heat exchanger not in service are closed. Do not leave all four cooling water
isolation valves open.
E. Seal Oil
The seal oil to the generator bearings is normally supplied by the lubricating system through a
separate line (tap OL-11) directly to the generator. In the event of low lube system pressure or lube
system shutdown for service, one of two seal oil pumps supply the oil required to seal in the
generator hydrogen. Under normal circumstances the AC motor driven pump (PQ3-1, 88QS-1) would
serve this function; however, if this AC motor should fail or if AC power is lost, the emergency DC
motor (88ES-1) is activated and drives the seal oil pump (PQ3-1 in “piggyback” AC/DC motor
configuration; PQ3-2 in separate AC and DC pumps). The AC motor (88QS-1) includes a heater
(23QS-1) to prevent condensation in the motor.

III. OPTIONAL DEVICES

A. Pressure Transmitters
The lubrication module may include the following additional Pressure transmitters (indication-only),
when selected by a customer as an option:

1. Differential pressure transmitters 96QQ-1 and 96QQ-2, which provide remote monitoring
capability of differential pressure across the oil filters (LF3-1 and LF3-2).

2. Pressure transmitter 96QH-1, which provides remote monitoring capability of bearing header
pressure.

7
GEK 111768 Lubrication System

3. Pressure transmitter 96QL-1, which provides remote monitoring capability of tank oil level.

These transmitters are indication-only devices. They do not alarm or trip the machine in case of a
failure, low pressure, level etc.

B. Lube Oil Conditioner

The Lube Oil System may also include a Lube Oil Conditioner when selected by a customer as an
option.The Lube Oil Conditioner is a stand-alone, kidney-loop Lube Oil Conditioning skid designed
specifically to remove particulate contamination (from 0.2 to 2 microns in size). Particulate
contamination in this size range is the precursor to varnish formation and accumulation. The
implementation of a Lube Oil Conditioner, together with monitoring and maintenance of the
Lubricating Oil additive package, will help prevent the formation and accumulation of varnish and
therefore varnish-related turbine trips (due to sticking hydraulic servo valves, etc.). The Lube Oil
Conditioning skid is a stand-alone, customer-located skid with all functions controlled by an onboard
PLC. There is no interface to the MKVI control system.

Oil entering the Lube Oil Conditioner skid is monitored for temperature via thermocouple LT-LC.
The oil then passes through the pump (PQ8) and into the pre-filter (LF3-6), which is monitored for
pressure by transducer 96QLC-1. The oil then passes into the Charging/Mixing vessel, which is
monitored for pressure by transducer 96QLC-2. Next, the oil moves to the final canister, containing
the post-filter (LF3-7), which is monitored for pressure by transducer 96QLC-3. Finally, oil exiting
the skid is monitored for pressure by transducer 96QLC-4. All of these devices communicate solely
with the PLC onboard the Lube Oil Conditioner skid.

g GE Energy
General Electric Company
www.gepower.com

8
DWG Number 145E4546 Rev A Released 11/12/2012 Page 1 of 3

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GE Proprietary Information - Class II (Internal) US EAR - NLR
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GE Proprietary Information - Class II (Internal) US EAR - NLR
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GE Proprietary Information - Class II (Internal) US EAR - NLR
Tab 10
 GE Power Systems

g GT Hyd & Lift Oil System

OILGEAR
PVG pump

P2 Dual Pressure
Compensator High
Pressure
Adjust
Low VPR3 - __
Pressure SET
Adjust 2750+-
VPR3 - __ 50.00
SETTING: PSIG OR
1800 PSIG 189.7+-
OR 124.146 3.448
BARG BARG

Revision Date: 03/06/2008 Property of GE Energy Learning Center - Proprietary Information for Training Purposes Only!

GE Power Systems

g GT Hyd & Lift Oil System

Maximum Volume
Adjustment

– Factory set -

** DO NOT ADJUST **

Revision Date: 03/06/2008 Property of GE Energy Learning Center - Proprietary Information for Training Purposes Only!
 GEK 111787a
Revised April 2009

GE Energy

Combined Hydraulic and Lift Oil System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 111787a Combined Hydraulic and Lift Oil System

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Combined Hydraulic and Lift Oil System GEK 111787a

I. GENERAL

The Gas Turbine Combined Hydraulic and Lift Oil system functions to provide fluid power required for
operating control components and to provide lift at the Gas Turbine and Generator bearings. The control
components include the Gas Valves (hydraulically actuated servo valves), inlet heat bleed valves, (on 9FB
units only) and the Inlet Guide Vanes-IGV’s (positioned by a hydraulic cylinder located on the turbine
base), and on Dual Fuel Gas Turbine units, the Liquid Fuel Valve (hydraulically actuated servo valve).

The major components of the system include the pumps and motors, accumulator, filters, and valves con-
tained in the manifold assembly. This document will describe how the system normally operates. See the
MLI 0434 Hydraulic/Lift Schematic for further details. For device settings, adjustments, and design fea-
tures, refer to the Control Specifications and the Device Summary included in this manual.

II. PUMP INLET AND DISCHARGE

Pressure regulated, filtered, and cooled lubrication oil from the main lube oil header in the A160 is used as
the hydraulic/lift oil, high-pressure fluid. The system is designed with two redundant parallel flow paths.
Under normal operation, only one circuit on the system is in use. Isolation valves are used to isolate either
of the circuits, however, maintenance should be performed off line. On the inlet to the system, pressure
switches (63HQ-6A, 63HQ-6B) signal an alarm, which prevents the hydraulic/lift pump motors (88HQ-1,
88HQ-2) from starting should there be insufficient inlet pressure. This feature will prevent the pumps from
cavitating. High-pressure fluid is then pumped to the supply manifold by one of the two pressure-compen-
sated, variable displacement pumps (PH1-1, PH2-1). Each pump is driven by its own AC electric motor.
The turbine operator controls the lead-lag sequence on the pumps. The pumps are constant pressure, vari-
able positive displacement axial piston pumps with built in dual pressure compensators (VPR3-1, VPR3-2).
The compensators act by varying the stroke of the pistons to maintain a set pump discharge. Each pump
has a high and low-pressure compensator setting. The high-pressure setting is used when lift oil supply
to the rotor bearings is needed. The low pressure setting is used when actuation of the gas valves and
IGV’s is required. Each pump/motor contains a heater, (23HQ-1, 23HQ-2), which prevents condensation
and freezing while the motors are not running. Air bleed valves are located immediately downstream of
the pump discharge to ensure rapid pressurization of the supply fluid. Each circuit contains an oil filter
(FH2-1, FH2-2) with integral differential pressure switches (63HF-1, 63HF-2). Hydraulic/lift oil supply
pressure relief valves (VR21-1, VR22-1) provide pressure relief in order to prevent component failure due
to over-pressurization, in the event that one of the pressure compensators fail or are inadvertently set wrong.

CAUTION

Pressure relief valves should be periodically checked for proper operation

III. LIFT OIL SUPPLY

Bearing lift oil is used to raise the turbine-generator rotor onto a thin, static oil film at each journal bearing
to minimize rotation friction losses the gas turbine starting means or turning gear must overcome. Lift
Oil Supply Isolation Valve (20QB-1) is a solenoid-operated valve. When energized, high-pressure oil is
allowed to flow to each of the turbine-generator bearings. Each bearing is equipped with a flow-regulating
valve to keep lift oil supply flow rate constant. In addition, the lift oil supply lines at the bearings contain
check valves to prevent bearing feed oil from back flowing into lift oil supply lines. 20QB-1 has a manual
override to be used if the solenoid fails. There is also a sensing line connected from downstream of the
solenoid to the compensator block. When the solenoid is open, the sensing line is pressurized, thus selecting
the high-pressure setting. Bearing Lift Oil Supply Pressure Switch (63QB-1) provides an alarm in the

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEK 111787a Combined Hydraulic and Lift Oil System

turbine control system if lift oil supply pressure is low, and will prevent the turning gear motor from starting
should there be insufficient pressure.

IV. HYDRAULIC OIL SUPPLY

Hydraulic Supply pressure is required to actuate the gas valves, IGV’s, inlet heat bleed valves (on 9FB units
only), and liquid fuel valve (for Dual Fuel units only). Each pump circuit contains a Hydraulic Oil Sup-
ply Pressure Regulating Valve (VPR4-3, VPR4-4). These pressure-regulating valves maintain hydraulic
pressure to hydraulic actuated components during normal operation, regardless of whether the pump is op-
erating at lift pressure or hydraulic pressure.

Hydraulic Discharge Oil Supply Pressure Switches (63HQ-1A, 63HQ-1B) are used to indicate if the lead
pump is not supplying enough pressure to the system. Should this be the case, the lag pump will be acti-
vated. Hydraulic Supply Low Pressure Relief Valve (VR23-2) is provided to prevent over-pressurization
of hydraulic supply components in the event pressure regulating valves fail or are set incorrectly. Off of the
hydraulic oil supply header is a single Accumulator (AH1-1) that stores hydraulic fluid for use in transient
conditions (e.g. valve actuation). The accumulator is in-service regardless of which pump is in operation.
The accumulator contains an isolation valve and flow control valve to control recharge rate. A Manual By-
pass Valve allows the operator to quickly depressurize and drain hydraulic oil supply header. This is useful
when resetting pump compensators, relief valves, or pressure regulators. The bypass valve also serves as
an accumulator drain valve.

CAUTION

Pressure relief valves should be periodically checked for proper operation

The (96HF-1 & 2) hydraulic oil filter differential pressure transmitters, and the (96HQ-1) hydraulic oil
supply pressure transmitter, are used for pressure monitoring in the Control Panel.

V. SYSTEM RISK OVERVIEW (FOR EU DIRECTIVE UNITS ONLY)

Details regarding operational risk related to the Hydraulic Power Unit (Combined Hydraulic and Lift Oil
System) can be found in the 0124 Equipment Residual Summary for this job and the A160 Operation and
Maintenance Manual, DIS-201, supplied by the skid vendor (Hydraulic Power Unit Section in applicable
manual).

VI. SYSTEM TROUBLESHOOTING

Symptom Possible Causes Possible Solutions

Lube oil pumps not operating Check pump orientation
Inlet isolation valve not open Open Valve FV-1A or FV-1B
No Inlet Pressure Motor 88HQ-1 not operating Switch on Motor
Standby circuit operating Read other inlet supply pressure
gauge
Usually caused by line trouble, Check source of power. Check
Motor will not Start such as single phasing at the overloads, fuses, controls, etc.
starter

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Combined Hydraulic and Lift Oil System GEK 111787a

Solenoid valve 20QB-1 is not Energize 20QB-1

energized
Solenoid valve 20QB-1 is Operate solenoid 20QB-1 using
damaged manual override
High pressure pump Set Compensator VPR3-1 and
compensator VPR3-1 or VPR3-2 VPR3-2 per Device Summary
High Pressure cannot be reached set incorrectly
Relief valve VR21-1 or VR22-1 Set relief valves VR21-1 and
set too low VR22-1 per Device Summary
Isolation valve FV-2A or FV-2B Open isolation valve FV-2A or
closed FV-2B
Motor rotation incorrect Check direction of rotation
Pressure regulating valve Set regulating valve VPR4-3 and
VPR4-3 or VPR4-4 is incorrectly VPR4-4 per Device Summary
set
Pump low pressure compensator Set compensator VPR3-1 and
VPR3-1 or VPR3-2 incorrectly VPR3-2 per Device Summary
set
Pressure regulating valve Replace pressure regulating
Hydraulic Pressure Cannot VPR4-3 or VPR4-4 is damaged valve VPR4-3 or VPR4-4
Be Reached
Relief valve VR23-2 set too low Set relief valve VR23-2 per
Device Summary
20QB-1 is energized Ensure that 20QB-1 is not
energized
Downstream check valve Identify and replace faulty check
permitting backflow into sensing valve
line
Frequent Component Oil Contaminants Replace filter elements. Verify
Replacement that oil varnishing is not an issue.
Motor Growling or Whining Bad Bearing Replace bearing
Pump cannot keep up with Set Max. Volume Stop
Unusually loud hammering
system demand, Max. Volume
noise during operation
Stop not set correctly
Unresponsive or sluggish Swash block saddle bearings Replace bearings
pump Control worn or damaged
Faulty Control Replace Control
Inlet Pressure is Low Ensure minimum 10 PSIG is
available at the Inlet.
Irregular or unsteady operation
Worn axial piston pump Replace Pump
Faulty output circuit components Check gas valves, turbine
bearings, etc.
Excessive vibration or Coupling halves are touching Adjust coupling halves so that
thrust loads they are not touching

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 111787a Combined Hydraulic and Lift Oil System

Misalignment/Side Loading Alignment should be 0.005"

Excessive flow from case drain
Total Indicator Reading (TIR)
Undersized or restricted case Do not use flowmeters, orifices,
Pressure spike on stroke drain line or coolers in case drain lines.
Damaged seals Verify that case drain line is
proper size.
Fluid cleanliness issue Resolve fluid cleanliness issue
Pump is contaminated via filter element replacement or
oil conditioning.

Shoe slamming into swashblock Verify that suction line is sized

Exceeding 10 psid case to inlet
Rounded shoe edges Shoes loose properly. Do not use suction
differential pressure
on balls Seal retainer bent strainers.

Fluid being siphoned from case Use loop seal above top of pump
Case not remaining full of oil due to improper case drain line casing to keep case full.
routing
Oil Bubbling Terminate case drain below
Aeration of oil
liquid surface in tank

GE Energy
General Electric Company
www.gepower.com

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4545 Rev - Released 10/25/2012 Page 1 of 4

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GE Proprietary Information - Class II (Internal) US EAR - NLR
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GE Proprietary Information - Class II (Internal) US EAR - NLR
g
GEK 106910a
Revised November 2010

GE Energy

Variable Inlet Guide Vane System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 106910a Variable Inlet Guide Vane System

I. GENERAL

Variable compressor inlet guide vanes (VIGV) are installed on the turbine to provide compressor pulsation
protection during startup and shutdown and also to be used during operation under partial load conditions.
The variable inlet guide vane actuator is a hydraulically actuated assembly having a closed feedback control
loop to control the guide vanes angle. The vanes are automatically positioned within their operating range
in response either to the control system exhaust temperature limits for normal loaded operation, or to the
control system pulsation protection limits during the start-up and shutdown sequences. On DLN units, the
IGV angle is modulated to control air flow to the combustors for DLN operation modes.

II. GUIDE VANE ACTUATION

The modulated inlet guide vane actuating system includes the following components: servo valve 90TV,
position sensors (LVDT) 96TV-1 and 96TV-2, and hydraulic dump valve VH3. These are shown on the
trip oil and IGV schematic diagrams in Volume III. When the inlet guide vane dump solenoid valve 20TV
in the trip oil circuit is energized, its drain ports are blocked thus allowing the trip oil to operate the dump
valve VH3. Electrical Trip solenoid functionality will be used incase of non trip oil system. Actuation of
the dump valve allows hydraulic oil to flow through servo valve 90TV. Control of 90TV will port hydraulic
oil through the dump valve to operate the variable inlet guide vane actuator.

For normal shutdown, inlet guide vane actuation is the reverse of the startup sequence; the compressor
bleed valves will open when the generator breaker is opened. The inlet guide vanes will ramp to the full
closed position as a function of temperature corrected speed.

In the event of a turbine trip, the compressor bleed valves will open and the inlet guide vanes will ramp to
the closed position as a function of temperature corrected speed.

III. PULSATION PROTECTION CONTROL

The inlet guide vanes are automatically positioned during a start-up and a shutdown sequence to avoid gas
turbine compressor pulsation. The pulsation limit is expressed as a function of IGV angle and corrected
speed, shown by the broken line on Figure 1. Corrected speed is a compressor design parameter that is a
function of the actual running speed of the compressor and the inlet air temperature. The control system
utilizes the measured variables of turbine speed and ambient temperature to determine the IGV angle and
automatically modulate them to that position.

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Variable Inlet Guide Vane System GEK 106910a

Figure 1. IGV Angle vs Corrected Speed and Load.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 106910a Variable Inlet Guide Vane System

IV. EXHAUST TEMPERATURE CONTROL

For applications such as a regenerative cycle or where there is a steam generator (boiler) in the gas turbine
exhaust, it is desirable to maximize the exhaust temperature. The control program for such turbines includes
an exhaust temperature control which automatically holds the IGV at a minimum angle during part-load
operations. A switch is provided to permit the operator to select this mode of operation.

V. OPERATION

During a normal start-up, the inlet guide vanes are held in the full-closed position (see the Control Spec-
ifications in this service manual for settings) until the proper temperature-corrected speed is reached. At
this time, the guide vanes will begin to open. A graphic representation of this action is shown in Figure 1.
The compressor bleed valves, which must operate in conjunction with the VIGVs to maintain compressor
surge margin during startup, will close when the generator breaker is closed.

When the VIGV temperature control mode is not activated, the guide vanes are held at the minimum full-
speed angle until the simple cycle VIGV exhaust temperature is reached. This temperature is the constant
CSKGVSSR. As the exhaust temperature rises, a value computed as the product of constant CSKGVTPG
times the difference between the actual exhaust temperature TTXM and CSKGVSSR is added to the mini-
mum angle, causing the VIGVs to open until they reach the maximum angle. This sets a minimum load
which the unit must reach before the VIGVs are allowed to open. This is necessary to avoid combustion
resonance and must not be changed.

For applications which require part load exhaust temperature control operation, the guide vanes are
switched to the “IGV temp control On” with a soft switch. In this mode the VIGVs remain at the minimum
full operating position until the base exhaust temperature limit is reached. At this point, they begin to
open to hold the exhaust temperature at this limit until they are full open when the exhaust temperature
control reverts to fuel modulation. In order to keep the fuel control and IGV control from trying to act
simultaneously, a fuel control bias is added to keep the fuel line slightly above the VIGV line. This bias
is the product of constant CSKGVBG times the difference between the maximum VIGV angle (constant
CSKGVMAX) and the VIGV reference CSRGV. This bias becomes zero when the VIGVs are fully open
and the fuel temperature control takes over.

The operator can activate or deactivate the VIGV temperature control mode at any time via the panel soft
switches. The control system will automatically reprogram the VIGVs to the correct position at a controlled
rate. Manual open/close soft switches are provided to allow the operator to manually position the VIGVs
between the minimum full speed angle and full Open. This control should only be used in special circum-
stances to limit the travel (amount opened). The manual control is limited to command an angle only when
less than that being called for by the automatic control system. In normal operation, the manual control is
set at full open. For applications requiring steam turbine warmup, the operator can select a desired exhaust
temperature and the IGV’s will modulate to achieve the setpoint. Refer to the control sequence program
for a detailed representation of the VIGV software.

VI. FAULT PROTECTION

The guide vane protection system will trip solenoid valve 20TV, initiate a fast normal shutdown and an-
nunciate if there is low hydraulic supply pressure, or the LVDT feedback is different from command, or
IGV position trouble is indicated. Should the inlet guide vane system be tripped under and one of the above
conditions, the SPEEDTRONIC* sequencing logic generates a signal which is used in the start check cir-
cuit to prevent any attempt to restart the turbine prior to eliminating the cause for the trip.

*Trademark of the General Electric Company.

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Variable Inlet Guide Vane System GEK 106910a

The primary IGV fault signal is generated by the “IGV not following CSRGV” algorithm, L86GVT. This
algorithm compares the difference between the VIGV position feedback CSGV and the reference signal
CSRGV to generate alarm signal, L86GVA if the IGV is not following the reference within the value of
LK86GVA1 given in the Control Specifications Settings. The alarm signal is annunciated if the difference
persists for time LK86GVA2 specified in the Control Specifications Settings. During part speed opera-
tion, a trip signal L86GVT is generated if the VIGV position feedback CSGV does not agree with the
speed reference CSRGV within the value of LK86GVT1 and for a time of LK86GVT2 given in the Con-
trol Specifications Settings. Trip signal L86GVT will deenergize 20TV, trip the turbine and annunciate an
alarm. During full-speed operation, trip logic L4GVTX will alarm and trip the turbine if the VIGV feed-
back CSGV falls below a minimum allowable full-speed value LK4IGVTX.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

GEK 106910a Variable Inlet Guide Vane System

g
GE Energy
General Electric Company
www.gepower.com

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Inlet Guide Vanes ( IGV )
a means to control air flow

inlet bell
mouth

air flow

2012 General Electric Company. All Rights Reserved. GE Energy Learning Center 1
IGV_Fund_4-2013
 IGV nomenclature

Elevation View Plan View

2012 General Electric Company. All Rights Reserved. GE Energy Learning Center 2
IGV_Fund_4-2013
Variable Inlet Guide Vane Arrangement
Hydraulic Servovalve in Operation

1 of 5
ST-GT_Servovalves_01-14 GE Energy Learning Center Proprietary 1
GE Title or job number
1/16/2014
 Hydraulic Servovalve in Operation

servovalve with a
double acting
control valve actuator

2 of 5
ST-GT_Servovalves_01-14 GE Energy Learning Center Proprietary 2
GE Title or job number
1/16/2014
 Hydraulic Servovalve in Operation

servovalve with a
single acting
control valve actuator

3 of 5
ST-GT_Servovalves_01-14 GE Energy Learning Center Proprietary 3
GE Title or job number
1/16/2014
 Hydraulic Servovalve in Operation

servovalve with a
single acting
control valve actuator

4 of 5
ST-GT_Servovalves_01-14 GE Energy Learning Center Proprietary 4
GE Title or job number
1/16/2014
Hydraulic Servovalve in Operation

5 of 5
ST-GT_Servovalves_01-14 GE Energy Learning Center Proprietary 5
GE Title or job number
1/16/2014
Tab 11
 DPT CPD

Diff
Gas Gas Analyzer Flow Meter Vent GCV 1
Supply DPT CPD
Customer Supplied Conditioning Equipment Purge Purge
PM1
Shut Off Valve Fuel Gas Conditioning Equipment
Vent GCV 2 DPT CPD
Purge Purge
PM4
Vent
Vent TE PT PT
GCV 3
Vent
Purge Purge
Strainer
ASV SRV
Turbine
AD 6
Compressor
Discharge

Combustion
9FA DLN 2.0 Gas Chamber
Only Fuel System End Cover
WG Number 207D3947 Rev - Released 4/20/2012

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GE Proprietary Information - Class II (Internal)

US EAR - NLR
DWG Number 145E4407 Rev A Released 10/30/2013 Page 1 of 1

8 7 6 5 4 3 2 SIZE

E
DWG. NO.

145E4407
SH.

1
REV.

A 1
REVISIONS
THIS DOCUMENT SHALL BE
NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT 13-10-23 SEE PLM
A ADDED KKS TAGS.
ARE THE SAME REVISION 13-10-23 SEE PLM
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION LEVEL AS INDICATED.
INCLUDED IN MLI 0438 APPLY.
3. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT
DESIGNER AND/OR PLANT INSTALLER.
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE
H CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH “PC” ARE H
GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
5. FOR UPSTREAM AND DOWNSTREAM EQUIPMENT, SEE MLI 0482.
6. INITIAL CARRIER GAS BOTTLES TO BE PROVIDED BY CHROMATOGRAPH
SUPPLIER. CARRIER GAS MUST BE 99.999% ULTRA HIGH PURITY HELIUM.
REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS.
7. INITIAL CALIBRATION GAS BOTTLE TO BE PROVIDED BY CHROMATOGRAPH
SUPPLIER. FOR CALIBRATION GAS CONSTITUENTS SEE MLI G023/EG26
PC
OUTLINE DRAWING. REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS. VTA
FG262
8. REGULATOR IS BOTTLE TYPE TO BE MOUNTED DIRECTLY ON GAS BOTTLE.
9. THREADOLET FOR CONNECTIONS FG257 & FG258 MUST BE SUPPLIED AND MBP06
INSTALLED BY OTHERS. GW001
VTA VTA
10. TUBING AND HEAT TRACE FROM CONNECTION POINTS [FG264 & FG265] TO G023-GC

MBP06
BR201
CONNECTION POINTS [FG259 & FG260] MUST BE PREINSULATED,
SELF-REGULATING HEAT TRACE TUBING. TUBING MUST BE FULLY ANNEALED,
G HIGH QUALITY [TYPE 304 OR 316, SEAMLESS] ASTM A269 OR EQUIVALENT.
HEAT TRACE IS REQUIRED TO HOLD SAMPLE LINE TEMPERATURE AT
G
MBP06

BR210
MBP06
100°F [38°C]. NC NC MBP06
AA501 AA502
11. ACTIVE AND SPARE SAMPLE STREAM TUBING MUST BE INSTALLED BY OTHERS
AND SHALL HAVE A MAXIMUM LENGTH OF LESS THAN 100 FT [30.48 M].
MBP06
12. SYMBOL DENOTES GAS CYLINDER CHANGEOVER REGULATOR. AA001
13. FG259 AND FG260 ARE 2.0 INCH [50.6 MM] THRU HOLES WITH HEAT SHRINK MBP06
JACKET WHICH WILL ALLOW THE PRE-INSULATED SELF-REGULATING HEAT BR401
TRACE TUBING TO BE FED THROUGH THE CABINET WALL AND TERMINATED
NO
ON THE SAMPLE CONDITION OVEN. PRIMARY
14. ALL KKS CODES DISPLAYED ON DRAWING ARE PREFIXED ACCORDING TO THE MBP06
SEE NOTE 6
PRACTICES IN THE GE KKS HANDBOOK, UNDER MLI 0438. AA010
EXAMPLE: VPR77-1
11MBN10 CP101 = FULL KKS SPECIFICATION MBP06

BR220
MBP06
11 = THE PREFIX CODE PER THIS EXAMPLE QJP05 BR410
MBN10 CP101 = SUFFIX SHOWN WITH DEVICE BB001

F PS SEE NOTE 12 MBP06

NO
F
MBP06 CP301 NO AA011
MBP06
63GCX-1 AA020

MBP06
BR202
MBP06 CHROMATOGRAPH CHROMATOGRAPH
ANALYZER ANALYZER

MBP05
BR411
AA002
[GCA] MBP07 MBP07 [GCB]
MBP06
AA002
BR402 MBP07 MBP07 AA004
MBP06 MBP06 BR405 BR406 MBP06 MBP06
NO
SECONDARY EG001 CQ003 EG003 CQ006
NO NO
30GCX-1 96FLW-1 30GCX-2 96FLW-2

MBP07
BR407
QJP05 SEE NOTE 6 MBP06 MBP06
MBP06 MBP06
BB002 CARRIER GAS MANIFOLD G023 PS EG004 GK002
EG002 GK001
MBP07 CP301 30GCX-4 RS-485-2
GAS SUPPLY 30GCX-3 RS-485-1 NO MBP07 MBP07 NO
63GCX-2
BR410 BR411
E SEE NOTE 5 E

MBP07
MBP07 MBP07

BR412
AA003 AA005
VTA
MBP07 MBP07
PI BR401 BR402
MBP03
BR201

MBP03 CP501
PI-GC-1
MBP07
SEE NOTE 9 QJP05 AA601
BB003 VPR78-1
PC
PC
FG257 PC SEE NOTE 7 & 8
FG264
MBP03 MBP03 NO FG259
ACTIVE SAMPLE STREAM
BR402 BR403
BR401 BR402
MBP03 MBP03 MBP03 SEE NOTES 10 & 11 SEE NOTE 13
MBP03 MBP03 MBP03
AA601 AA901 AA001
AT001
D VPR76-1 D
ACTIVE SAMPLE PROBE G023

VTA

PI
MBP04
BR201

MBP04 CP501
PI-GC-2

SEE NOTE 9
PC PC
FG258 FG265 PC
MBP04 MBP04 NC SPARE SAMPLE STREAM FG260
C BR402 BR403 C
BR401 BR402
MBP04 MBP04 MBP04 SEE NOTES 10 & 11 SEE NOTE 13
MBP04 MBP04 MBP04
AA601 AA901 AA001
AT001
VPR76-2
SPARE SAMPLE PROBE G023

PC
GAS SUPPLY SAMPLE CONDITIONING OVEN G023
FG261
MBP05
SEE NOTE 5
VTA BR201

B B
FUEL GAS CHROMATOGRAPH G023

1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671

IT. NOMENCLATURE IDENT
LIST OF COMPLEMENTARY DOCUMENTS
GE CLASS II (INTERNAL NON-CRITICAL)
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. DIMENSIONS ARE IN INCHES
DRAWN
LINAN, CLAUDIA 12-05-23
g GE Energy GAS TURBINE

ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE TOLERANCES ON CHECKED

A ENERGY GAS TURBINE PROPRIETARY TECHNICAL INFORMATION THAT

BELONGS TO THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA), LLC
AND/OR THEIR AFFILIATES, WHICH HAS BEEN PROVIDED SOLELY FOR
2 PL DECIMALS ±
3 PL DECIMALS ±
ANGLES ±
ENGRG
SEE PLM
ABLES, JOHN
12-05-23
12-05-23 DIAG,SCHEM PP-FUEL GAS
A
ISSUED
THE EXPRESS REASON OF RESTRICTED PRIVATE USE. ALL PERSONS, FRACTIONS ±
SEE PLM 12-05-23
FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL BE
DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED
QUALITY CHROMATOGRPAH
TO MAKE NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER
FIRST MADE FOR: IPS 721613 4035
THIRD ANGLE PROJECTION FOR ANY, OR ALL SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED
IN WRITING BY THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA), SIZE CAGE CODE DWG NO
LLC AND/OR ITS AFFILIATES.
E 145E4407

DISTR
SIM TO:

TO
NONE SCALE SHEET 1 of 1

8 7 6 5 4 3 2 1
GE Proprietary Information - Class II (Internal) US EAR - NLR
 g
GEK 111865a
Revised, January 2008

GE Energy

Gas Chromatograph for Fuel Gas

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.
GEK 111865a Gas Chromatograph for Fuel Gas

The Gas Chromatograph (GC) is primarily used with the 7/9FA and 7/9FB model Gas Turbines to
accommodate variations in gas fuel properties from the design value. The advanced technology fuel
nozzles and combustion systems used in GE Gas Turbines are sensitive to the pressure ratio across the
fuel nozzle tip. Damaging combustion dynamics and flame instabilities can occur if the pressure ratio
across the fuel nozzle tip moves out of the specified design range. Gas fuels with the same MWI but
different compositions will require the same upstream and downstream pressure across the fuel nozzle tip
to supply the same heat input to the combustion system. Variations of gas fuel properties are controlled
by adjusting gas fuel temperature to maintain a constant MWI. With this adjustment the pressure ratio
across the fuel nozzle tip can be held within acceptable limits. Since fuel gas composition and the
associated MWI varies with the properties of the supply gas, the GC acts as the primary protection
against these dynamics and flame instabilities.

The Gas Chromatograph Skid contains two separate Gas Chromatograph Analysers (GCA’s – are
typically Danalyser 700’s produced by Emerson Process Analytical Company) housed in one cabinet.
Each GC Analyser sends two sets of 4-20 mA signals to up to two Gas Turbine MARK VI’s. A set of
signals comprises: Low Wobbe Index (LWI – Range: 1180 to1300); Specific Gravity (SG – Range: .525
to .675)) and Lower Heating Value (LHV – Range: 850 to 1175 BTU/SCF). Each GCA is programmed to
analyse a fuel gas mixture every 4 (four) minutes. The GCA’s are setup to lead-lag out of phase so a
signal gets sent to each MARK VI, every 2 (two) minutes. Having two GCA’s in one cabinet allows for
doubling of the frequency of data and provides redundancy in case one of the GCA’s fails. A single Gas
Chromatograph Cabinet can be used to control 2 (two) Gas Turbines as long as the GC sample is
extracted upstream of the main gas line “tee-off” point. If multiple Gas Turbines are present, then a
combination of signal multipliers, repeaters and amplifiers will be required to be broadcast the 4-20 mA
signals to the remaining Gas Turbines.

Operation of the GC begins when the fuel gas sample is filtered and pressure reduced at the pipeline. As
it enters the fuel gas probe it is then mixed with a 99.999% pure carrier gas of Helium (He) and sent to
the GCA ovens for preheating. The hot fuel gas/helium mixture is then sent thru the GCA columns. The
rate of passage of each fuel gas component varies depending on their characteristic viscosities. As each
component passes thru the columns, its quantity is detected and recorded. It consists of the mole % of:
Nitrogen (N2); Carbon Dioxide (CO2); Methane (CH4); Ethane (C2H6); Propane (C3H8); Iso- and N-
Butane (C4H10); Iso- and Neo- and N-Pentane (C5H12) and all heavier Carbon hydrocarbons reported as
C6+. At multiple gas turbine sites, VSCA Cards in the MARK VI’s and PSCA Cards in the MARK VIe’s
allow the Modbus registers containing these individual digital gas component mole %’s from both GC
“A” and GC “B” to be accessed via RS485 cables and 2 intermediary PLC’s. The LWI, SG and LHV are
calculated in the GC based on these compositions and are also sent digitally along with the gas
compositions. The Mark VIe then calculates the Modified Wobbe Index (MWI) using the specific gravity
(SG), LHV (Lower Heating Value) and the temperature found at FG1 with the following formula:

LHV
MWI = (T@FG1*SG)1/2

The GCA’s are periodically calibrated with a calibration gas. Calibration is typically recommended each
morning of operation. A general alarm and calibration gas cylinder empty signal is also available to be
sent to the MARK VI’s to warn operators to change the gas bottles at the skid.

2 © General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.

 Gas Chromatograph for Fuel Gas GEK 111865a

THIS PAGE INTENTIONALLITY LEFT BLANK

© General Electric Company, 2008. GE Proprietary Information. All Rights Reserved. 3

GEK 111865a Gas Chromatograph for Fuel Gas

g GE Energy
General Electric Company
www.gepower.com

4 © General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.

 GEK 116384
April 2009

GE Energy

Controls SSOV (Safety Shut off Valve) System Testing

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 116384 Controls SSOV (Safety Shut off Valve) System Testing

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Controls SSOV (Safety Shut off Valve) System Testing GEK 116384

TABLE OF CONTENTS

I. GENERAL OVERVIEW ............................................................................................................. 4

II. DESIGN OVERVIEW................................................................................................................... 4

A. Hardware Description ............................................................................................................. 4
B. Software Description................................................................................................................ 5

III. FUNCTIONAL BLOCK DIAGRAM ......................................................................................... 7

IV. ALARMS ....................................................................................................................................... 9

LIST OF TABLES

Table 1. Table– Alarm List and Suggested Operator Response ............................................................ 9

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEK 116384 Controls SSOV (Safety Shut off Valve) System Testing

I. GENERAL OVERVIEW

The Safety Shut Off System is comprised of two separate valves, a Stop Valve (SSOV) and a Vent Valve
(SSOVV). These valves are located outdoors upstream of the Fuel Gas Module (FG1). They stop and
vent (to atmosphere) the fuel gas to the GT in the event of Fire Detection, Hazardous Gas Detection, and
Emergency Stop activation. The intent is to be able to shut off and isolate the fuel gas supply and vent
the fuel gas within the piping between the SSOV and the A160/0991 (Gas Fuel Module). The SSOV is
normally closed valve. The Vent valve is a normally open vent valve. Class VI seal capability - NFPA
requires an automatic stop of fuel supply in emergency conditions.

NOTE

The SSO vent is associated with Hazardous release of gas and should release the
hazardous gas in an area free of ignition sources.

II. DESIGN OVERVIEW

A. Hardware Description

The Safety Shut Off System is comprised of two separate valves, a Stop Valve (SSOV) and a Vent Valve
(SSOVV). These valves are located outdoors upstream of the Fuel Gas Module (FG1). They stop and
vent (to atmosphere) the fuel gas to the GT in the event of Fire Detection, Hazardous Gas Detection,
and E Stop activation.

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Controls SSOV (Safety Shut off Valve) System Testing GEK 116384

B. Software Description

Open and Closed limit switches on both the SSOV and Vent valve. Verification of SSOV open and Vent
valve closed for START and during GT operation, as the unit will trip on NOT OPEN SSOV, or NOT
CLOSED Vent Valve during unit operation. The SSOV closes on GT Shutdown, following closure of
SRV. Vent Valve remains closed during trips and fired shutdowns. SSOV opens only prior to next GT
Start. Unit cannot be started unless vent valve sensed closed. The SSOV closes and Vent valve opens
following detection of fire or a gas leak. SSOV can only be manually opened and vent valve manually
closed following a fire or a gas leak event.

SSOV stop valve slew rate from full closed to full open must not exceed (4 sec)

SSOV stop valve slew rate from full open to full close must not exceed (1 sec)

SSOV vent valve slew rate from full closed to full open must not exceed (1 sec)

SSOV vent valve slew rate from full open to full close must not exceed (4 sec)

Must vent P1 cavity to 1 barg in a max time of 15 sec with a target time of 10 sec

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 116384 Controls SSOV (Safety Shut off Valve) System Testing

System Testing

System testing is performed offline at least once a year. Operator activates SSOV Leak test by pressing
button on HMI.

Before start of SSOV system, it is verified that the system is offline.

In order to isolate fuel and vent from P1 cavity, verify SSOV stop valve VS4-4, SSOV vent valve
VA13-8, aux stop valve, and stop/ratio valve are closed. If not true, alarm (L30SSOVLT_A) operator
and inhibit SSOV system from continuing.

TEST 1A: Check for 20VG-8 to shuttle correctly: Open SSOV vent valve 20VG-8 and check slew rate
and limit switch connections. Alarm (G1\LSSOVLT1A_A) and inhibit startup if in incorrect positions.
Allows P1 cavity to vent for system testing. If limit switches are in incorrect positions, then 20VG-8
did not shuttle correctly

TEST 1B: Check that P1 vents below specified pressure in given time: Verify P1 pressure drops to 5
psig (KSSOVLT1B_P) in 30 sec (KSSOVLT1B_TD) seconds. Alarm (G1\LSSOVLT1BA) and inhibit
SSOV System Test continuation and startup if pressure did not drop to spec. This is to check P1 cavity
can be vented in specified time.

TEST 2A: Check for increasing pressure in P1 from leaking SSOV stop valve 20VS4-4: Wait 120
(KSSOVLT2A_TD) seconds and if P1 pressure is 5 psig, (KSSOVLT2A_P) alarm (LSSOVLT2A_A)
operator that TEST 2 failed and inhibit SSOV System Test continuation and startup. If P1 χB psig, it
indicates that SSOV Stop valve leaks faster then the SSOV vent valve can vent.

TEST 2B: Check for 20VG-8 to shuttle correctly: Close SSOV vent valve 20VG-8 and check slew rate
and limit switch connections. Alarm (LSSOVLT2B_A) and inhibit SSOV System Test continuation
and startup if in incorrect positions. Seals P1 cavity to be refilled. If limit switches are in incorrect
positions, then 20VG-8 did not shuttle correctly

TEST 3: Check for 20VS4-4 to shuttle correctly: Open SSOV stop valve 20VS4-4 and check slew rate
and limit switch connections. Alarm (LSSOVLT3A_A) and inhibit SSOV System Test continuation
and startup if in incorrect positions. This is to pressurize P1.

Once all tests have passed, permit GT startup

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Controls SSOV (Safety Shut off Valve) System Testing GEK 116384

III. FUNCTIONAL BLOCK DIAGRAM

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 7

GEK 116384 Controls SSOV (Safety Shut off Valve) System Testing

8 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Controls SSOV (Safety Shut off Valve) System Testing GEK 116384

IV. ALARMS

Table 1. Table– Alarm List and Suggested Operator Response

Recommended
Operator Interface
Signal Possible Causes Operator Level
Alarm Message
Actions
L30SSOVLT_A SSOV Leak SSOV stop valve Alarm operator Level-2
Test Out of VS4-4, SSOV vent and inhibit SSOV
Position valve VA13-18, System test from
aux stop valve, and continuing
stop/ratio valve are
not closed.
LSSOVLT1A_A SSOV Vent valve 20VG-8 shuttles Alarm and inhibit Level-2
not Shuttle Properly incorrectly: Open startup if in
SSOV vent valve incorrect positions.
20VG-8 and check
slew rate and limit
switch connections
LSSOVLT1BA P1 Pressure too high P1 does not vents below Alarm and inhibit Level-2
specified pressure in SSOV System Test
given time: Verify P1 continuation and
pressure drops to 5 psig startup if pressure
(KSSOVLT1B_P) did not drop to
in 30 sec spec.
(KSSOVLT1B_TD)
seconds
LSSOVLT2A_A Didn’t vent P1 in Increasing pressure in Alarm operator Level-2
TIME P1 from leaking SSOV that TEST 2
stop valve 20VS4-4. failed and inhibit
P1 Pressure is 5 psig SSOV System Test
continuation and
startup.
LSSOVLT2B_A SSOV Vent valve 20VG-8 shuttles Alarm and inhibit Level-2
NOT shuttle incorrectly: Close SSOV System
properly SSOV vent valve Test continuation
20VG-8 and check and startup if in
slew rate and limit incorrect positions.
switch connections.
LSSOVLT3A_A SSOV NOT Shuttle 20VS4-4 shuttles Alarm and inhibit Level-2
properly incorrectly: Open SSOV System
SSOV stop valve Test continuation
20VS4-4 and check and startup if in
slew rate and limit incorrect positions
switch connections.
L33VS4_4ALM FG safety shut off Indication of failed Inhibit Startup Level-2
Valve position fault SSOV valve

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 9

GEK 116384 Controls SSOV (Safety Shut off Valve) System Testing

L33VG8_ALM FG safety shut off Indication of failed Inhibit Startup Level-2

Vent valve position SSOV Vent valve
fault
LESD1_P_ALM Vent pressure too Isolate and vent Alarm operator of Level-2
high pressure too high Valve failure
LSSOVLT_A Leak Test Failed Test 1, or 2 or 3 failed Alarm operator of Level-2
Leak Test Failed

GE Energy
General Electric Company
www.gepower.com

10 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4544 Rev A Released 1/10/2013 Page 1 of 4

8 7 6 5 4 3 2 SIZE

E
DWG. NO.

145E4544
SH.

1
REV.

A 1
REVISIONS
THIS DOCUMENT SHALL BE
NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT 1. IN SHEET 1, NOTES 16 REVISED
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION ARE THE SAME REVISION LEVEL
INCLUDED IN MLI 0438 APPLY. AS INDICATED. 2. IN SHEET 2, PURGE PRESSURE RATIO
3. THE TERM "OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT TRANSMITTERS ADDED
DESIGNER AND/OR PLANT INSTALLER.
A 3. IN SHEET 3, AUX STOP VALVE ADDED 13-01-07 SEE PLM
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE ECR0019833
H CONNECTION BY OTHERS, CONNECTIONS NOT MARKED WITH ”PC” ARE GEE ECO0086374 H
GEE CONNECTIONS, REQUIRED NO INTERFACE BY OTHERS, AND ARE NOT P.SANTHIYAGU
SHOWN ON MLI 4063.
5. ALL DEVICES AND DEVICE SETTINGS OTHER THAN THOSE ASSOCIATED WITH
THE FUEL GAS CONTROL VALVES (MLI’S 0507 AND 0509 ) AND PRESSURE
TRANSMITTERS (557T) ARE FOR REFERENCE ONLY. SEE DEVICE SUMMARY
(MLI 0414) FOR RECOMMENDED SETTINGS, RATINGS AND RANGES.
6. FOLLOW AGA REPORT 11 FOR INSTALLATION AND REQUIREMENTS FOR PIPE
LENGTH PRECEDING AND FOLLOWING METER TUBE, MG2-4.
7. A TEMPORARY CONICAL STRAINER SUPPLIED BY G.E. IS TO BE INSTALLED (SEE
MLI A179).
8. REFER TO GAS FUEL STRAINER INSPECTION, CLEANING AND MAINTENANCE
RECOMMENDATIONS INCLUDED ON MLI 0438.
9. CONNECTIONS BETWEEN COMBUSTOR END COVERS AND THE FUEL GAS
SUPPLY MANIFOLDS MUST BE PITCHED SO THAT THERE ARE NO LOW POINTS.
ALL LIQUIDS WILL DRAIN TO EITHER THE FUEL MANIFOLD FOR ALL LOWER
HALF COMBUSTION END COVERS AND/OR TO THE COMBUSTION CAN FOR ALL
G UPPER HALF COMBUSTION END COVERS. LIQUID MUST NOT BE PERMITTED
TO DRAIN TO THE LOWER CANS.
G
10. LOW POINT DRAIN BLANKED FLANGE CONNECTION.
11. SLOPED LINE FROM GAS COMPARTMENT AND MANIFOLD TO LOW
POINT CONNECTION.
12. N/A.
13. OTHERS MUST PROVIDE AN ANSI CLASS VI ISOLATION VALVE UPSTREAM OF
G.E. SUPPLIED EQUIPMENT IN ORDER TO ALLOW THIS EQUIPMENT TO BE
ISOLATED FOR MAINTENANCE ETC.
14. N/A.
15. GAS FUEL MUST MEET GAS FUEL SPECIFICATION PROVIDED ON MLI 0438.

16. PRESSURE TAP FOR DELTA P PRESSURE TRANSMITTERS (MLI 557T)

MUST BE LOCATED SUCH THAT THE LINE WILL SLOPE CONTINUOUSLY BACK
A1
FROM THE PRESSURE TRANSMITTER ARRANGEMENT TO THE MANIFOLD AND
COMPRESSOR DISCHARGE CASING.

F 17. STRAINER VENTING VALVE HAS PROVISIONS FOR A LOCK AND MUST BE
LOCKED IN THE CLOSED POSITION DURING OPERATION. IN ORDER TO
F
REMOVE BASKET FOR REPLACEMENT OR CLEANING FOLLOWING
SHUTDOWN, ISOLATE FUEL GAS SUPPLY VIA AN UPSTREAM ANSI CLASS VI
ISOLATION VALVE, VENT PRESSURE IN STRAINER AND ATTACHED PIPING BY
OPENING THE VALVE. VERIFY PRESSURE HAS COMPLETELY VENTED BY
CHECKING PRESSURE GAUGE PI-FG-1 AND BY MONITORING OUTPUT
TRANSMITTER PT 96FG-1 BEFORE REMOVING STRAINER COVER IN
ACCORDANCE WITH STRAINER MANUFACTURERS INSTRUCTIONS IN SERVICE
MANUAL.

18. ISOLATION VALVES HAVE LOCKING PROVISIONS. VALVES TO BE

LOCKED IN THE OPEN POSITION PRIOR TO OPERATION.
19. THE SAFETY SHUTOFF VALVE AND SAFETY SHUTOFF VENT VALVE MUST BE
INSTALLED OUTDOORS. THE PIPING VOLUME BETWEEN THE OUTLET OF
SAFETY SHUTOFF VALVE AND FG1 MUST NOT EXCEED 63.5 CUBIC FEET
(1.8 CUBIC METERS). THE SAFETY SHUTOFF VALVE AND SAFETY SHUTOFF
VENT VALVE MUST BE INSTALLED SUCH THAT THEY ARE PROTECTED
E AGAINST ICING.
E

D D

C C

B B

1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671

IT. NOMENCLATURE IDENT
LIST OF COMPLEMENTARY DOCUMENTS
GE CLASS II (INTERNAL NON-CRITICAL)
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY
DIMENSIONS ARE IN INCHES
DRAW N
LIÑAN, CLAUDIA 12-09-27
 GE Energy GAS TURBINE
TOLERANCES ON CHECKED

A © COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. 2 PL DECIMALS ±

3 PL DECIMALS ± ENGRG
SEE PLM
ELURIPATI, RAVI
12-09-27
12-09-27
A
ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE ENERGY GAS
TURBINE PROPRIETARY TECHNICAL INFORMATION THAT BELONGS TO THE GENERAL
ANGLES ±
FRACTIONS ± ISSUED
SEE PLM 12-09-27
DIAG, SCHEM PP-FUEL GAS
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR THEIR AFFILIATES, WHICH HAS QUALITY
BEEN PROVIDED SOLELY FOR THE EXPRESS REASON OF RESTRICTED PRIVATE USE.
ALL PERSONS, FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL FIRST MADE FOR: ML-9K1WFA163-1 0422
THIRD ANGLE PROJECTION
BE DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED TO MAKE SIZE CAGE CODE DWG NO
NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER FOR ANY, OR ALL
SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY THE GENERAL E 145E4544

DISTR
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. SIM TO:

TO
NONE SCALE SHEET 1 of 4

8 7 6 5 4 3 2 1
GE Proprietary Information - Class II (Internal) US EAR - NLR
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8 7 6 5 4 3 2 SIZE

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145E4544
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REV.

A 1

H H

A2
INSTRUMENT AIR
(BY OTHERS)

VTA VTA PDT

96GN-1
G PC PC PC H L G
FG2 FG3 FG7
NO NO
FULL BORE ORIFICE FG166
TYPICAL 6 PLACES SEE NOTE 16
AD-5A FROM MLI 0417, CLG & SLG
TO TO
AIR SYSTEM, “ LINE AD-5A”
PIGTAIL PIGTAIL
# 17 #18 Ø 0.136 [3.45 MM] 557T
TYPICAL 18 PLACES

D5 MG1-1

SEE
NOTE 9
F 0637 F
TC COMBUSTION CHAMBER
INSTRUMENT AIR
(BY OTHERS) PT-G1-2

TC TC
PC SEE NOTE 19
FG440 SEE NOTE 7 PT-G1-1 PT-G1-3

FG138 PDT
96GN-2
20VG-8
ZS H L
0962 PITCH PITCH
33VG-8
SEE NOTE 11 NO NO
VTA ZS SEE NOTE 10 FG167
SEE NOTE 16
E VTA VTA 33VG-9
TO TO AD-5B FROM MLI 0417, CLG & SLG E
PC
PIGTAIL PIGTAIL 557T AIR SYSTEM, “ LINE AD-5B”
FG438 Ø 0.136 [3.45 MM]
# 17 #18 TYPICAL 18 PLACES
FO
PC VA13-18
FG439
SAFETY SHUT OFF VENT VALVE 0572
PM1 MG1-2
SEE NOTE 7
INSTRUMENT AIR
(BY OTHERS) SEE
PC PC FG139 NOTE 9 PDT
PC SEE NOTE 19
FG428B FG428A FG427 96GN-3
COMBUSTION CHAMBER
H L
0962 PITCH PITCH
SEE NOTE 11 NO NO
D 20VS4-4 SEE NOTE 10 FG168 D
ZS SEE NOTE 16
AD-5C FROM MLI 0417, CLG & SLG
33VS4-4 TO TO AIR SYSTEM, “LINE AD-5C”
FT PIGTAIL PIGTAIL Ø 0.136 [3.45 MM] 557T
ZS # 17 #18 TYPICAL 18 PLACES
96FM-4 SEE NOTE 6
SEE NOTES 13 & 15 33VS4-5
VTA VTA
PC PC
FG21 FG426
GAS FUEL
MG2-4 PM4
SUPPLY MG1-3
FC SEE NOTE 7
PC PC VS4-4
FG20 FG425 SEE
PC
SEE NOTE 6 FUEL GAS FLOW METER 0639 FG140 NOTE 9
FG1
COMBUSTION CHAMBER
SAFETY SHUT OFF VALVE 0572
PITCH
C 0962 PITCH
SEE NOTE 11
C
SEE SHEET 3
ACCESSORY MODULE SEE NOTE 10
GAS COMPARTMENT

GAS FUEL PIPING 0962

557T

TURBINE COMPARTMENT 1634

B B

A A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.


DRAWN
GE Energy
E 145E4544

DISTR
LIÑAN, CLAUDIA

TO
ISSUED
SEE PLM
SCALE SHEET
2 of 4

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A 1

PC PC
FG3 FG7

AL-87
AL-88
ASW-44 PT PT PT NO
H DL-51 PI H
DL-52 96FG-2A 96FG-2B 96FG-2C
FG-2
SEE NOTE 18 IA-2 TO MLI 0420, COOLING
WATER SYSTEM
2 2 2
3 3 3 NO PA-10 FROM MLI 0477, FUEL
1 1 1 PURGE, “LINE PA-10”
IA-1 TO MLI 0477, PURGE AIR
SYSTEM

PDS PI

63FGD-1 FG-1

G NO G
PDI PT
FG-3 96FG-1

NC 2 VTA
2
3 3

S
1 20VG-1
A3 1
NO NO

FO
SEE NOTE 17 0507
PC ZS OH-2
20VS4-1 ZS OH-2
FG2 0509
33VS4-1 33VG-4
F NC F
ZS H PI
OH-18
33VS4-2 H D5
OH-17 VA13-15
PC VTA VTA
GPL-6 GPL-1 GPL-2
FG1
NO
FC FC FC
VS4-1
TC TC TC
VSR-1 VGC-1 SEE SHEET 4
FTG-1A FTG-1B FTG-1C SEE SHEET 4
SEE NOTE 8 FG138
0507
FROM MLI 0477, FUEL PA-4
PURGE, “LINE PA-4”
OH-2

E OH-2
E
0509

OH-17
H PI
TO MLI 0434 OH-19 OH-19
HYDRAULIC OIL, “LINE OH-19” PM1
GPL-3

HYDRAULIC OIL, “LINE OH-17”

NO
FC

TO MLI 0434
VGC-2 SEE SHEET 4
TO MLI 0434 OH-18
HYDRAULIC OIL, “LINE OH-18” FG139
D D

OH-2
0509

H PI
TO MLI 0434, HYDRAULIC OH-20 OH-20
OIL, “LINE OH-20” PM4
GPL-4

NO
FC

C VGC-3
C
SEE SHEET 4

SEE NOTE 18 FG140

FROM MLI 0477, FUEL PA-6
FROM MLI 0434,HYDRAULIC OH-2
PURGE, “LINE PA-6”
OIL, “LINE OH-2”
NO

B B

ACCESSORY MODULE GAS COMPARTMENT

A A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.


DRAWN
GE Energy
E 145E4544

DISTR
LIÑAN, CLAUDIA

TO
ISSUED
SEE PLM
SCALE SHEET
3 of 4

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A 1

H H

PDI
FH7-1

OH-2 IN
OUT

FH7-1

G G
90SR-1

OH-17 20FGS-1

VH5-1 ZE
96SR-1

GPL-1

F ZE F
96SR-2

VSR-1
SEE SHEET 3

E E

D PDI
PDI PDI
D
FH8-2 FH8-3
FH8-1

OH-2 IN OH-2 IN
OH-2 IN OUT OUT
OUT
0509
0509
0509 FH8-2 FH8-3
FH8-1

20FGC-2 65GC-2 20FGC-3 65GC-3

65GC-1 OH-19 OH-20
C OH-18 20FGC-1
C

ZE ZE
ZE VH5-3 VH5-4
VH5-2
96GC-4 96GC-7
96GC-1

GPL-3 ZE GPL-4 ZE
GPL-2 ZE
96GC-5 96GC-8
96GC-2

ZE ZE
ZE
96GC-6 96GC-9
96GC-3

B VGC-2 VCG-3
B
VGC-1
SEE SHEET 3 SEE SHEET 3
SEE SHEET 3

A A
GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.


DRAWN
GE Energy
E 145E4544

DISTR
LIÑAN, CLAUDIA

TO
ISSUED
SEE PLM
SCALE SHEET
4 of 4

8 7 6 5 4 3 2 1
GE Proprietary Information - Class II (Internal) US EAR - NLR
 g
GEK 116535a
Revised, December 2011

GE Energy

Gas Fuel System

DLN 2.0+ 9FA

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company.
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
GEK 116535a Gas Fuel System

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

TABLE OF CONTENTS

I. MAINTENANCE AND INSPECTION .................................................................................................... 4

A. General Notes......................................................................................................................................... 4
B. Annual Maintenance and Inspection...................................................................................................... 5
C. During Hot Gas Path Inspection or Major Outage............................................................................... 11
II. GENERAL ................................................................................................................................................ 13
III. GAS FUEL SYSTEM............................................................................................................................... 13
A. Routing of Vent Lines by Customer/Installer ...................................................................................... 13
B. Gas Strainer.......................................................................................................................................... 14
C. Pressure Gauges ................................................................................................................................... 15
D. Gas Fuel Vent Solenoid Valve VA13-15............................................................................................. 15
E. Thermocouples (FTG - 1A, 1B & FTG-2A, 2B) ................................................................................. 15
F. Auxiliary Stop Valve (VS4-1) - ONLY FOR HEATED FUEL JOBS ................................................ 15
G. Pressure Transducer 96FG-1................................................................................................................ 15
H. Gas Flow Measurement (96FM-1 or 96FM-4) .................................................................................... 15
I. Gas Purge Pressure Ratio Monitoring (96GN-1, 96GN-2, 96GN-3)................................................... 16
J. Calibration of Fuel Gas Pressure Transducers, 96FG-2A, 2B, 2C ...................................................... 16
K. Safety Shut Valves............................................................................................................................... 16
IV. GAS FUEL OPERATION ....................................................................................................................... 16
A. Diffusion Mode.................................................................................................................................... 16
B. Sub-Piloted Pre-Mix ............................................................................................................................ 17
C. Piloted Pre-Mix.................................................................................................................................... 17
D. Piloted Pre-Mix.................................................................................................................................... 17
V. CHAMBER ARRANGEMENT .............................................................................................................. 20
VI. COMBUSTION REFERENCE TEMPERATURE............................................................................... 20
VII. DLN-2.0+ INLET GUIDE VANE OPERATION .................................................................................. 20
VIII. DLN-2.0+ INLET BLEED HEAT........................................................................................................... 20
IX. DLN-2.0+ GAS FUEL PURGE SYSTEM.............................................................................................. 21
X. FLAME DETECTION............................................................................................................................. 21
XI. IGNITION SYSTEM ............................................................................................................................... 21
XII. CONTINGENCY OPERATION ............................................................................................................ 21
A. Unit Trip .............................................................................................................................................. 21
B. False Start ............................................................................................................................................ 23
XIII. DLN-2.0+ SYSTEM ANNUNCIATOR TROUBLESHOOTING CHART......................................... 23

LIST OF FIGURES

Figure 1. DLN-2.0+ Gas Fuel System.................................................................................................................. 13

Figure 2. Diffusion to SPPM................................................................................................................................ 17
Figure 3. Pilot Premix to Premix.......................................................................................................................... 18
Figure 4. Premix to Pilot Premix.......................................................................................................................... 19
Figure 5. Gas Fuel Purge System ......................................................................................................................... 22

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 3

GEK 116535a Gas Fuel System

I. MAINTENANCE AND INSPECTION

A. General Notes
This section outlines recommended maintenance and inspections for the Gas Fuel System equipment.
It is expected that each customer will create unit-specific maintenance and inspection procedures and
that these procedures include but not be limited to the recommendations of sections B and C. These
procedures shall include but not be limited to the following: Lock-out/Tag-out of current/voltage,
instrument air, and/or hydraulic/trip oil; gas fuel isolation, venting, and purging; identification of
hazards (gases, oils, stored energy…etc.); and required personal protective equipment (safety
goggles, hazardous gas detectors…etc.).

NOTE

The gas module has lockable isolation valves in the instrument air and hydraulic oil
supply lines to facilitate Lock-out/Tag-out of these systems.

WARNING

EACH OF THE VALVES LISTED IN THE FOLLOWING SECTIONS

ARE SPRING ASSISTED. PLEASE REVIEW AND FOLLOW ALL
MANUFACTURES LITERATURE BEFORE PERFORMING ANY
INSPECTION, DISASSEMBLY AND/OR MAINTENANCE ON THESE
VALVES.

***DANGER***

DO NOT ATTEMPT TO REMOVE THE ACTUATOR OF A

VALVE UNLESS THE VALVE IS IN THE FAIL SAFE
POSITION AND THE SPRING IS UNLOADED.

WARNING

FOLLOWING A SHUT DOWN GAS FUEL IS NOT AUTOMATICALLY

PURGED FROM THE GAS FUEL SUPPLY PIPING. GAS FUEL WILL
BE PRESENT IN ALL GAS FUEL PIPING UP TO THE GAS TURBINE.
SITE SAFE WORK PRACTICES SHALL APPLY FOR PROPER GAS
FUEL ISOLATION, VENTING, AND PURGING OF THE GAS FUEL
PIPING PRIOR TO ANY MAINTENANCE ACTIVITY.

4 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

WARNING

FAILURE TO PROPERLY MAINTAIN THE COMPONENTS OF THE

GAS FUEL SYSTEM MAY RESULT IN UNSAFE OPERATION,
HAZARDS TO PERSONNEL, AND EQUIPMENT DAMAGE.

The sections to follow are based on normal operation and assumes that the instrument air, the
hydraulic oil, and the gas fuel are in accordance with their applicable GEIs and/or GEKs. If
contamination of these systems is suspected or a known issue exist, increased maintenance and
inspections may be required.

This Section covers the major Gas Fuel System equipment. It is assumed that industry standards for
annual calibration and verification of pressure, temperature, and flow instrumentation will be
performed.

It is recommended that all seat and seal lapping be preformed by the original equipment supplier or a
facility approved by the original equipment supplier.

B. Annual Maintenance and Inspection

The following maintenance and inspections are recommended annually or during a Combustion
Inspection, whichever occurs first. The following recommendations are not in any particular order.
Following a repair, one or more of these recommendations may need to be performed again, in
particular slew time and leak tests.

1. Safety Shut Off Stop Valve (VS4-4)

a. Inspect limit switch set points. Adjust as required.

b. Inspect for loose wires and chafing. Gently tug on each wire at its termination point.

c. Perform valve slew rate check. If the valve does not meet specification, check the packing for
over tightness, bushings for wear/galling, actuator linkage for wear or lack of lubrication, and
the actuator cylinder for damage.

d. Perform a bubble (snoop) leak test on the valve body and check overboard packing vent for
excessive leakage. This will require upstream and downstream pressure applied to the valve
of approximately 50 PSIG air or nitrogen. A leak rate above 1 bubble per minute at the
packing vent is considered excessive. Tighten or replace packing as required.

e. Perform a bubble (snoop) leak test on the valve actuator while the actuator is in the actuated
position. Normal site supply instrument air pressure is recommended for this test. Replace
seals as required.

f. Inspect the actuator solenoid and quick exhaust valve vents for blockage and/or debris. Clean
as required.

g. If the site has an issue with gas fuel contamination inspect valve disk and seat for corrosion
and/or wear. Clean, lap, or replace as required.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 5

GEK 116535a Gas Fuel System

h. If the valve is removed to facilitate any of the above perform the recommendations outlined
in Section C.

NOTE

It is important that a dial indicator be used to measure the shaft runout prior to and
following actuator mounting. The dial indicator shall be used to observe the shaft
runout as the valve is rotated from closed to open. The use of a dial indicator will
ensure that the actuator does not put excessive force on the valve bearings.

Refer to the Safety Shut off Valve Operations & Maintenance manual for additional information
regarding valve removal, installation, troubleshooting, inspection, and refurbishment.

2. Safety Shut Off Vent Valve (VA13-18)

a. Inspect limit switch set points. Adjust as required.

b. Inspect for loose wires and chafing. Gently tug on each wire at its termination point.

c. Perform valve slew rate check. If the valve does not meet specification, check the packing for
over tightness, bushings for wear/galling, actuator linkage for wear or lack of lubrication, and
the actuator cylinder for damage.

d. Perform a bubble (snoop) leak test on the valve body. Tighten or replace packing as required.

e. Perform a bubble (snoop) leak test on the valve actuator while the actuator is in the actuated
position. Normal site supply instrument air pressure is recommended for this test. Replace
seals as required.

f. Inspect the actuator solenoid and quick exhaust valve vents for blockage and/or debris. Clean
as required.

g. If the site has an issue with gas fuel contamination inspect valve ball and seat for corrosion
and/or wear. Clean, lap, or replace as required.

h. If the valve is removed to facilitate any of the above perform the recommendations outlined
in Section C.

NOTE

It is important that a dial indicator be used to measure the shaft runout prior to and
following actuator mounting. The dial indicator shall be used to observe the shaft
runout as the valve is rotated from closed to open. The use of a dial indicator will
ensure that the actuator does not put excessive force on the valve bearings.

Refer to the Safety Shut off Vent Valve Operations & Maintenance manual for additional
information regarding valve removal, installation, troubleshooting, inspection, and
refurbishment.

6 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

3. Gas Fuel Strainer

a. Inspect strainer mesh for signs of corrosion or tearing. Replace if damaged.

b. Inspect seals for damage. Replace if damaged.

If the gas fuel strainer has signs of corrosion, tearing, or excessive debris this is indicative of gas
fuel that does not meet the cleanliness requirements of the applicable gas fuel GEI/GEKs. The
source of any corrosion, tearing, or debris should be identified and removed prior to gas turbine
operation.

Refer to the Manufactures Gas Fuel Strainer Operations & Maintenance manual and the Gas
Fuel System Strainer - Inspection, Cleaning and maintenance Recommendations for Heavy Duty
Gas Turbines GEK for additional information regarding removal, installation, troubleshooting,
inspection, and cleaning.

4. Auxiliary Stop Valve (VS4-1)

NOTE

The presence of an Auxiliary Stop Valve is conditionally based on the gas fuel
temperature requirements. This valve may or may not be present.

a. Inspect limit switch set points. Adjust as required.

b. Inspect for loose wires and chafing. Gently tug on each wire at its termination point.

c. Perform valve slew rate check. If the valve does not meet specification, check the packing for
over tightness, bushings for wear/galling, actuator linkage for wear or lack of lubrication, and
the actuator cylinder for damage.

d. Perform a bubble (snoop) leak test on the valve body and check overboard packing vent for
excessive leakage. This will require upstream and downstream pressure applied to the valve
of approximately 50 PSIG air or nitrogen. A rate above 1 bubble per minute at the packing
vent is considered excessive. Tighten or replace packing as required.

e. Perform a bubble (snoop) leak test on the valve actuator while the actuator is in the actuated
position. Normal site supply instrument air pressure is recommended for this test. Replace
seals as required.

f. Inspect the actuator solenoid and quick exhaust valve vents for blockage and/or debris. Clean
as required.

g. If the site has an issue with gas fuel contamination inspect valve disk and seat for corrosion
and/or wear. Clean, lap, or replace as required.

h. If the valve is removed to facilitate any of the above perform the recommendations outlined
in Section C.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 7

GEK 116535a Gas Fuel System

NOTE

It is important that a dial indicator be used to measure the shaft runout prior to and
following actuator mounting. The dial indicator shall be used to observe the shaft
runout as the valve is rotated from closed to open. The use of a dial indicator will
ensure that the actuator does not put excessive force on the valve bearings.

Refer to the Aux Stop Valve Operations & Maintenance manual for additional information
regarding valve removal, installation, troubleshooting, inspection, and refurbishment.

5. Stop Ratio Valve (VSR-1)

a. Check servo valve null current.

b. Check servo valve resistance.

c. Check LVDT resistance.

d. Inspect terminal board for loose wires and chafing. Gently tug on each wire at its termination
point.

e. Inspect for signs of hydraulic oil leakage. Tighten fittings and replace o-ring seals as
required. Inspect inside of the return spring housing.

f. Inspect trip oil relay cartridge for contamination, varnish, or seal damage. Check the trip
relay for cleanliness and freedom of operation. A small amount of dirt can cause the relay to
stick, clean or replace as required.

g. Replace hydraulic oil filter.

h. Inspect push rod ends for slop.

i. Inspect guide rods and bushings for wear. Lubricate if required.

j. Perform valve slew rate check. Reference the valve O&M Trouble Shooting section if the
valve slew time does not meet specification.

k. Perform valve linearity test. Reference the valve O&M Trouble Shooting section if the valve
does not move to within 0.50% of the commanded position.

l. Perform valve step response/stability check. Contact GE Energy Service if the valve’s step
response is unstable.

m. Perform a bubble (snoop) leak test on the valve body and check overboard packing vent for
excessive leakage. This will require upstream and downstream pressure applied to the valve
of approximately 50 PSIG air or nitrogen. A leak rate above 1 bubble per minute at the
packing vent is considered excessive. Tighten or replace packing as required.

n. If the site has an issue with gas fuel contamination, inspect valve disk and seat for corrosion
and/or wear. Clean, lap, or replace as required.

8 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

o. If the valve is removed to facilitate any of the above perform a seat leakage test per the
procedures outlined in ANSI / FCI 70-2-1991. If the valve exceeds its allowable leak rate as
defined by ANSI/FCI 70-2-1991 clean, lap, replace, and/or center the ball and/or seat as
required.

NOTE

There are two types of SRVs available, a Class IV metal-seated SRV or a Class VI
TCM Ultra soft-seated SRV. The type of SRV applied is based on the site-specific
gas fuel temperature requirements. To insure proper operation and sealing of the
SRV it is important to follow all of the manufactures installation recommendations.
Additionally, the Class VI TCM Ultra soft-seated SRV is prone to seat leakage if
the following is not adhered to. When installing the Class VI TCM Ultra soft-seated
SRV the valve shall be well supported and the inlet flange shall be installed in the
piping first, the outlet flange shall be allowed to float. The bolts shall be tightened
in a star pattern using incremental torques. Also, in the event of excessive seat
leakage, flipping the seat of a Class VI TCM Ultra soft-seated SRV may allow it to
reseal. However, if the seat has any visible signs of deformation, nicks, cuts, or any
other defects it should be replaced.

Refer to the Stop Ratio Valve Operations & Maintenance manual for additional information
regarding valve removal, installation, troubleshooting, inspection, and refurbishment.

Changes in servo valve null bias, valve slew time, and valve dynamic response may be an
indication of hydraulic oil contamination or varnish. Refer to the applicable lube oil and
hydraulic oil GEK for additional information on contamination and varnish recognition and
mitigation. If contamination or varnish is a know site issue, a regular servo valve replacement
program is recommended.

Following any maintenance of the Stop Ratio Valve a LVDT calibration shall be performed
using the turbine control panel regulator calibration feature. If the site has performance fuel
heating it is recommend that a second calibration be performed at the first hot restart.

6. P2 Cavity Vent Valve (VA13-15)

a. Inspect limit switch set points. Adjust as required.

b. Inspect for loose wires and chafing. Gently tug on each wire at its termination point.

c. Perform valve slew rate check. If the valve does not meet specification, check the packing for
over tightness, bushings for wear/galling, actuator linkage for wear or lack of lubrication, and
the actuator cylinder for damage.

d. Perform a bubble (snoop) leak test on the valve body. Tighten or replace packing as required.

e. Perform a bubble (snoop) leak test on the valve actuator while the actuator is in the actuated
position. Normal site supply pressure is recommended for this test. Replace seals as required.

f. Inspect the actuator solenoid vents for blockage and/or debris. Clean as required.

g. If the site has an issue with gas fuel contamination inspect valve disk and seat for corrosion
and/or wear. Replace as required.
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 9
GEK 116535a Gas Fuel System

h. If the valve is removed to facilitate any of the above perform the recommendations outlined
in Section C.

Refer to the Gas Fuel Module (MLI 0991) or Accessory Module (MLI A160) Operations &
Maintenance manual for additional information regarding valve removal, installation,
troubleshooting, inspection, and refurbishment instructions.

7. Gas Control Valves (VGC-X)

a. Check servo valve null current.

b. Check servo valve resistance.

c. Check LVDT resistance.

d. Inspect terminal board for loose wires and chafing. Gently tug on each wire at its termination
point.

e. Inspect for signs of hydraulic oil leakage. Tighten fittings and replace o-ring seals as
required. Inspect inside of the return spring housing.

f. Inspect trip oil relay cartridge for contamination, varnish, or seal damage. Check the trip
relay for cleanliness and freedom of operation. A small amount of dirt can cause the relay to
stick, clean or replace as required.

g. Replace hydraulic oil filter.

h. Perform valve slew rate check. Reference the valve O&M Trouble Shooting section if the
valve slew time does not meet specification.

i. Perform valve linearity test. Reference the valve O&M Trouble Shooting section if the valve
does not move to within 0.50% of the commanded position.

j. Perform valve step response/stability check. Contact GE Energy Service if the valve’s step
response is unstable.

k. Perform a bubble (snoop) leak test on the valve body and check overboard seal vent for
excessive leakage. This will require upstream and downstream pressure applied to the valve
of approximately 50 PSIG air or nitrogen. A leak rate of 100 cc/min at the overboard seal
vent is considered excessive and the stem seals should be replaced.

l. If the site has an issue with gas fuel contamination inspect plug, plug stem, stem seals and
seat for corrosion and/or wear. Return the valve back to manufacture if required.

m. If the valve is removed to facilitate any of the above perform a seat leakage test per the
procedures outlined in ANSI / FCI 70-2-1991. If the valve exceeds its allowable leak rate as
defined by ANSI/FCI 70-2-1991 return it to the manufacture for repair.

Refer to the Gas Control Valve Operations & Maintenance manual for additional information
regarding valve removal, installation, troubleshooting, inspection, and refurbishment
instructions. Also, the Gas Control Valve Operations and Maintenance manual contains
refurbishment contact information.

10 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

Following any maintenance of a Gas Control Valve a LVDT calibration shall be performed using
the turbine control panel regulator calibration feature. If the site has performance fuel heating it
is recommend that a second calibration be performed at the first hot restart.

C. During Hot Gas Path Inspection or Major Outage

The following maintenance and inspections are recommended during a Combustion Inspection or
Major Outage and are in addition to the recommendations outlined in Section B.

1. Safety Shut Off Stop Valve (VS4-4)

a. Inspect disk and seat for signs of corrosion or wear. Clean, lap, or replace as required.

b. Inspect the disk bolts for tightness.

c. Inspect actuator linkage for signs of wear. Lubricate or replace as required.

d. Inspect actuator cylinder and piston for sign of excessive wear. Replace cylinder, seals and/or
bushings as required.

e. Perform a seat leakage test per the procedures outlined in ANSI / FCI 70-2-1991. If the valve
exceeds its allowable leak rate as defined by ANSI/FCI 70-2-1991 clean, lap, replace, and/or
float (center) the disk and/or seat as required.

2. Safety Shut Off Vent Valve (VA13-18)

a. Inspect disk and seat for signs of corrosion or wear. Clean, lap, or replace as required.

b. Inspect actuator linkage for signs of wear. Lubricate or replace as required.

c. Inspect actuator cylinder and piston for sign of excessive wear. Replace cylinder, seals and/or
bushings as required.

d. If the valve exceeds its allowable leak rate as defined by ANSI/FCI 70-2-1991 clean, lap,
replace, and/or center the ball and/or seat as required clean, lap, and replace the ball and/or
seat as required.

3. Auxiliary Stop Valve (VS4-1) (IF APPLICABLE, IF NOT REMOVE)

a. Inspect disk and seat for signs of corrosion or wear. Clean, lap, or replace as required.

b. Inspect the disk bolts for tightness.

c. Inspect actuator linkage for signs of wear. Lubricate or replace as required.

d. Inspect actuator cylinder and piston for sign of excessive wear. Replace cylinder, seals and/or
bushings as required.

e. If the valve exceeds its allowable leak rate as defined by ANSI/FCI 70-2-1991 clean, lap,
replace, and/or center the ball and/or seat as required clean, lap, replace, and/or float (center)
the disk and/or seat as required.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 11

GEK 116535a Gas Fuel System

4. Stop Ratio Valve (VSR-1)

The SRV should be returned to the manufacture for refurbishment. In addition to all of the
Annual Maintenance and Inspections listed in section B the SRV manufacture will perform the
following.

a. Replace the servo valve.

b. Replace the actuator stem seals.

c. Replace the trip relay cartridge.

d. Replace the hydraulic cylinder seals.

e. Inspect the LVDT core and rods for wear and replace if required.

f. Replace the rod ends.

g. Inspect the return spring for wear and replace if required.

h. Inspect the valve ball and seat, replace as required.

i. Perform a seat leakage test per the procedures outlined in ANSI / FCI 70-2-1991.

Refer to the Stop Ratio Valve Operations and Maintenance manual for refurbishment contact
information.

5. Gas Control Valves (VGC-X)

The Gas Control Valves should be returned to the manufacture for refurbishment. In addition to
all of the Annual Maintenance and Inspections listed in Section B the Gas Control Valve
manufacture will perform the following.

a. Replace the servo valve.

b. Replace the actuator stem seals.

c. Replace the actuator balancing seals.

d. Replace the trip relay cartridge.

e. Replace the hydraulic cylinder seals.

f. Inspect the LVDT core and rods for wear and replace if required.

g. Inspect the return spring for wear and replace if required.

h. Inspect the plug, plug stem, and seat, replace as required.

i. Perform a seat leakage test per the procedures outlined in ANSI / FCI 70-2-1991.

Refer to the Gas Control Valve Operations and Maintenance manual for refurbishment contact
information.

12 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

II. GENERAL

The dry low 2.0+ (DLN-2.0+) control system regulates the distribution of fuel delivered to a multi-nozzle
combustor arrangement. The fuel flow distribution to each combustion chamber fuel nozzle assembly is a
function of combustion reference temperature (TTRF1) and IGV temperature control mode. Diffusion,
Sub-piloted Premix, piloted premix, and premix flame are established by changing the fuel flow
distribution in the combustor. By a combination of fuel staging and shifting of burning modes from
diffusion at ignition through full pre-mix at high load, dramatically lower NOx emissions can be achieved
above firing temperatures of 2,270°F.

III. GAS FUEL SYSTEM

A. Routing of Vent Lines by Customer/Installer
FG2 and FG3 are potential sources of flammable atmosphere. Refer to MLI 0422 Fuel Gas Schematic
for additional information.

The gas fuel system consists of the gas fuel stop/speed ratio valve, diffusion gas control valve, PM4
gas control valve, and PM1 gas control valve. (Refer to Figure 1).

Figure 1. DLN-2.0+ Gas Fuel System

The stop/speed ratio valve (SRV) is designed to maintain a predetermined pressure (P2) at the control
valve inlet. The diffusion, PM4, and PM1 gas control valves (GCVs) regulate the desired gas fuel
flow delivered to the turbine in response to the command signal FSR from the SPEEDTRONIC *
panel. The dry low NOx mode of operation will determine how the control valves stage fuel to the
multi-nozzle combustion system. The auxiliary stop valve is used to provide class 6 sealing when
heated fuels are used.

*
Trademark of the General Electric Company.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 13

GEK 116535a Gas Fuel System

The stop/speed ratio valve and gas control valves are monitored for their ability to track the command
set-point. If the valve command set-point differs from the actual valve position by a prescribed
amount for a period of time, an alarm will annunciate to warn the operator. If the condition persists
for an extended amount of time, the turbine will be tripped and another alarm will annunciate the trip.

B. Gas Strainer
A strainer is provided in the fuel gas supply line upstream of the stop/speed ratio valve. This gas
strainer is a last chance strainer. The purpose of the strainer is to stop foreign objects or materials that
may prevent the gas turbine from operating/shutting down safely. The strainer is not designed for
continual fuel gas clean up. The strainer utilizes a differential pressure switch 63FGD-1 or transducer
96FGD-1 along with a differential pressure gauge installed across the strainer to monitor blockage.
The pressure switch or transducer initiates an alarm to the turbine control panel if the gas differential
pressure increases beyond a specified setting. During operation, the strainer differential pressure
should be closely monitored. If an alarm is registered, the strainer should be inspected and if required
cleaned. All strainer contamination shall be considered abnormal and the source of contamination
shall be verified. All strainer maintenance shall be performed in accordance with the manufacturer's
recommendations. Each strainer is equipped with a lockable vent valve that vents to FG2, see MLI
0422 for additional information on location of strainer vent valve and instructions for venting the fuel
gas to a safe area.

Prior to strainer maintenance, the upstream and downstream pressure shall be zero. To determine the
down stream pressure, utilize the pressure gauge FG-1 and pressure transducer 96FG-1. The upstream
pressure can be verified by using the differential pressure gauge FG-3 and differential pressure switch
63FGD-1 or transmitter 96FGD-1. When using the differential pressure gauge/switch/transmitter to
determine that the upstream pressure is zero, the downstream pressure shall be zero; the sensing lines
to the differential devices shall be open; and the pressure equalizer valve shall be closed.

The fuel gas strainer may be one of the following types Y Strainer, Duplex Strainer, or Multi Element
Strainer. All three designs utilize a metal mesh filtration element.

1. Y Type Strainer

The Y Type Strainer is basket type strainer; it is designed as a single unit with one strainer
basket.

2. Duplex Strainer

The duplex strainer is a basket type strainer; it is designed as a single unit with two separate
baskets and a flow transfer valve. The transfer valve is designed to allow fuel gas to flow
through only one basket at a time. If a high differential pressure is observed, the transfer valve
allows for the transfer to a clean basket.

3. Multi-Element Strainer

The Multi-Element Strainer is designed as single unit with multiple elements arranged in parallel
to the fuel gas flow path, each element is fed with fuel gas simultaneously. In order to perform
maintenance on the Multi-Element strainer, the unit must be removed from the fuel gas piping.
Therefore it may be necessary to place temporary pipe supports in the fuel gas pipe spools
upstream and downstream of the unit.

14 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

C. Pressure Gauges
One differential pressure gauge (PDI-FG-3) measures the difference between the inlet and outlet
pressures of the gas strainer.

Three pressure gauges, with hand valves, are installed in the fuel gas supply line. The upstream
pressure gauge (PI-FG-1) measures the pressure of the gas entering the stop/speed ratio valve; the
intermediate pressure gauge (PI-FG-2) measures P2 pressure ahead of the gas control valve; and the
downstream gauges (PI-D5, PI-PM-1, PI-PM-4) measures the pressure as the gas leaves the gas
control valves.

D. Gas Fuel Vent Solenoid Valve VA13-15

This solenoid valve vents the volume between the stop/speed ratio valve and the gas control valves
when the solenoid (20VG-1) is de-energized. The solenoid is energized and the vent valve closed
when the master control protection circuit is energized and the turbine is above the cooldown slow
roll speed. It will be closed and remain closed during gas fuel operation. The vent is open when the
turbine is shut down because the stop/speed ratio valve and gas control valves have metal plugs and
metal seats and therefore, are not leak tight. The vent insures that during the shutdown period, fuel
gas pressure will not build up between the stop/speed ratio valve and gas control valves, and that no
fuel gas will leak past the closed gas control valves to collect in the combustors or exhaust.

If the vent valve fails during normal operation, the SRV will continue to maintain constant pressure,
P2. This is accomplished by opening further, making up any lost flow through the vent valve.

E. Thermocouples (FTG - 1A, 1B & FTG-2A, 2B)

Up stream of Stop/Speed Ratio Valve (SRV) are two Dual element thermocouples FTG-1A/1B, FTG-
2A/2B which sense the temperature and send an electrical signal back to the controller.

F. Auxiliary Stop Valve (VS4-1) - ONLY FOR HEATED FUEL JOBS

The auxiliary stop valve provides additional shutoff of the fuel gas flow when required by either
normal operation or emergency conditions. The auxiliary stop valve is pneumatically actuated valve
that is spring biased to the closed position. The auxiliary stop valve has an integral trip relay valve
20VS4-1 that is located between the pneumatic supply air and the valve actuator. When 20VS4-1 is
energized, pneumatic pressure will force the auxiliary stop valve to the open position by overcoming
the spring bias. Upon a shut down or trip, 20VS4-1 is de-energized and the pneumatic pressure
supply is shut off to the valve actuator, the remaining pneumatic pressure in the valve actuator is
released through a quick exhaust port in 20VS4-1, and the valve closes.

G. Pressure Transducer 96FG-1

This pressure transducer is installed in the gas piping upstream of the gas stop/speed ratio valve and
is used to initiate an alarm when the fuel pressure becomes too high or low.

H. Gas Flow Measurement (96FM-1 or 96FM-4)

The Gas Flow Metering is achieved by one of the following types of fuel flow meters: an Orifice
meter (MG2-1) or a Coriolis meter (MG2-4).

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 15

GEK 116535a Gas Fuel System

For the Orifice meter a mass flow transmitter, 96FM-1 and gas fuel meter tube / orifice (MG2-1) are
used to measure natural gas flow. The device, 96FM-1 operates on the principles of measuring delta
pressure across the gas fuel meter orifice, static gas pressure and gas temperature. These measured
parameters establish the mass flow when the flow area ratio (beta) is known (Constant). Gas fuel flow
is only used for monitoring and display in the gas turbine control system.

For the Coriolis meter, the meter measure mass flow by taking advantage of the Coriolis Effect; the
inertial effects that arise as a fluid flows through a tube are directly proportional to the mass flow of
the fluid. In a Coriolis Flowmeter, vibration is induced in the process-fluid-filled flow tube(s), then
the mass flow rate is captured by measuring the difference in the phase of vibration between one end
of the flow tube and the other. The flow rate is transmitted via flow transmitter 96FM-4.

I. Gas Purge Pressure Ratio Monitoring (96GN-1, 96GN-2, 96GN-3)

When a gas passage is being purged, a minimum gas purge pressure ratio must be maintained to
ensure positive airflow across all the fuel nozzles. This pressure ratio is sufficient to overcome any
combustion can-to-can pressure variation. The differential pressure transmitters measure the gas
manifold pressure relative to compressor discharge pressure. These pressures are used for monitoring
and alarm in the control system.

J. Calibration of Fuel Gas Pressure Transducers, 96FG-2A, 2B, 2C

The fuel gas pressure transducer, 96FG, is a pressure transducer with a dc voltage output directly
proportional to pressure input in psig. It incorporates solid state circuits and an amplifier in the
transducer case. A diode is connected across the output of the transducer. This prevents any
possibility of a spurious signal driving the transducer amplifier negative, out of its normal operating
range. The transducer is normally factory adjusted and calibrated; however, the calibration must be
checked in the field and necessary readjustment made to meet the volts-output versus pressure-input
requirements, as specified in the Control Specifications.

K. Safety Shut Valves

The Safety Shut Valves are two separate valves, a Stop Valve (VS4-4) and a Vent Valve (VA13-18).
These valves are located outdoors, upstream of the Fuel Gas Compartment/Module (FG1). They stop
and vent (to atmosphere) the fuel gas to the GT in the event of Fire Detection, Hazardous Gas
Detection, and E Stop activation. Each valve is pneumatically actuated via a 3-way solenoid valve,
20VS4-4 Stop Valve and 20VG-8 Vent valve. Each valve has limit switches to indicate open and
closed position; 33VS4-4 / 33VS4-5 Stop Valve and 33VG-8 / 33VG-9 Vent Valve.

IV. GAS FUEL OPERATION

There are three basic modes of distributing gas fuel to the DLN-2.0+ combustor. These modes are
described below:

A. Diffusion Mode
In this mode, all the gas fuel is directed to the five diffusion tips in each of the combustors. At this
time the premix passages PM1 and PM4 are purged with CPD air.

Diffusion is the normal mode of operation from ignition to L14HS and unloading from L14HS to
flameout.

16 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

B. Sub-Piloted Pre-Mix
In this mode the fuel is split between the two gas control valves. The G2 PM1 split ramps up in the
higher end of this mode to optimize combustion dynamics. Attention must be made not to exceed the
defined split-level at the high end of this mode due to hardware concerns. Sub piloted premix is the
combustion mode between L14HS and FXKTH loading and FXKTH-FXKTHDB to L14HS. Sub
piloted premix mode is the steady state FSNL mode.

C. Piloted Pre-Mix
In this mode, the fuel is split between the three gas control valves. To split between G2 and G3, the
split would be 20/80. It is normal to run the pre-mix burners slightly off even-split to optimize
combustion dynamics at the expense missions. Piloted premix is the combustion mode between
combustion reference temperature FFXKTH and FXKTM-loading, and FXKTM-FXKTMDB to
FXKTH-FXKTHDB unloading.

D. Piloted Pre-Mix
In pre-mix, all the fuel is directed to tG2 and G3, which feed PM1 and PM4 respectively. To give an
even premix split between G2 and G3, the split would be 20/80. It is normal to run the premix
burners slightly off even split to optimize combustion dynamics at the expense of emissions.

The diagrams in Figure 1, Figure 2 and Figure 3 show how fuel flow is controlled while transferring
between the various combustion modes.

Figure 2. Diffusion to SPPM

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 17

GEK 116535a Gas Fuel System
Figure 3. Pilot Premix to Premix
18 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
 Gas Fuel System GEK 116535a
Figure 4. Premix to Pilot Premix
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 19
 GEK 116535a Gas Fuel System

V. CHAMBER ARRANGEMENT

The 9FA+ employs 18 similar combustors. For each machine there are two spark plugs and four flame
detectors in selected chambers with crossfire tubes connecting adjacent combustors. Each combustor
consists of a five nozzle/cover assembly, forward and aft combustion casings, flow sleeve assembly,
multi-nozzle cap assembly, liner assembly, and transition piece assembly.

VI. COMBUSTION REFERENCE TEMPERATURE

The combustion reference temperature signal (TTRF1) is generated by a calculation in the DLN-2.0+
control software. This equation calculates TTRF1 as a function of the median exhaust temperature
(TTXM), the compressor discharge pressure (CPD), and the inlet bell mouth temperature (CTIM). This
calculated temperature represents a reference for combustor mode sequencing and fuel split scheduling
and is not a true indication of actual machine firing temperature. A careful checkout of the combustion
reference temperature during start-up is required. The initial loading of the turbine should be performed
with “pilot premix base” selected on and samples of the combustion reference temperature calculation
should be compared to values listed in the control specifications. The combustion reference temperature
should match the control specification numbers within 20°F. Differences greater than 20°F may indicate
an error in the calculation.

VII. DLN-2.0+ INLET GUIDE VANE OPERATION

The DLN-2.0+ combustor emission performance is sensitive to changes in fuel to air ratio. The
combustor was designed according to the airflow regulation scheme used with inlet guide vane (IGV)
temperature control. Optimal combustor operation is crucially dependent upon proper operation along the
predetermined temperature control scheme. Controlled fuel scheduling will be dependent upon the state
of IGV temperature control. IGV temperature control on can also be referred to as combined cycle
operation while IGV temperature control off is referred to as simple cycle operation.

VIII. DLN-2.0+ INLET BLEED HEAT

Operation of the gas turbine with reduced minimum IGV settings can be used to extend the Premix
operating region. Reducing the minimum IGV angle allows the combustor to operate at a firing
temperature high enough to support premix operation.

Inlet bleed heating (IBH), through the use of recirculated compressor discharge airflow, is necessary
when operating with reduced IGV angles. Inlet heating protects the compressor from stall by relieving the
discharge pressure and by increasing the inlet air stream temperature. Other benefits include anti-icing
protection due to increased pressure drop across the IGVs.

The inlet bleed heat system regulates compressor discharge bleed flow through a control valve and into a
manifold located in the compressor inlet air stream. The control valve varies the inlet heating air flow as a
function of IGV angle. At minimum IGV angles the inlet bleed flow is controlled to a maximum of 5.0%
of the total compressor discharge flow. As the IGVs are opened at higher loads, the inlet bleed flow will
proportionally decrease until shut off.

The IBH control valve is monitored for its ability to track the command set-point. If the valve command
set-point differs from the actual valve position by a prescribed amount for a period of time, an alarm will
annunciate to warn the operator. If the condition persists for an extended amount of time, the inlet bleed
heat system will be tripped and the IGV' minimum reference will be raised to the default value.

20 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

The IBH system monitors the temperature rise in the compressor inlet airflow. This temperature rise
serves as an indication of bleed flow. Failure to detect a sufficient temperature rise in a set amount of
time will cause the inlet bleed heat system to be tripped and an alarm annunciated.

IX. DLN-2.0+ GAS FUEL PURGE SYSTEM

The purge system is required to maintain a positive flow of compressor discharge air through the gas fuel
nozzle passages when gas flow is nonexistent. Failure to provide purge flow when required will damage
components in the combustion system. The Gas Fuel Purge System is shown below.

The Gas Fuel Purge System is designed such that it provides a positive purge to a required manifold
which is not in use during Gas Turbine operation. The purge pressure ratio is mechanically set, by pipe
and orifice sizing as a function of fuel nozzle effective area. The purge pressure must be of a magnitude
(greater than Pcc) to prevent backflow through nozzles and prevent cross-talk between fuel nozzles and
combustion chambers. The gas fuel/gas fuel purge junction and downstream piping are designed to
support plugged flow (minimal mixing of fuel and air). These components and piping have also been set
out so that stagnant and unswept volumes have been minimized. Furthermore, the gas fuel/gas fuel purge
junction has been designed so that the introduction of purge into a gas-filled manifold does not cause an
unacceptably high load swing. This is primarily achieved by introducing a soft purge — VA13-1, -2, -3, -
4, -5, and -6 are opened over 35 seconds. A continuous purge is provided to Diffusion at a pressure ratio
of 0.98 (P4 to PCD) and to Pre-Mix (PM1 and PM4) at 0.955 (P4 to PCD).

X. FLAME DETECTION

Reliable detection of the flame location in the DLN-2.0+ system is critical to the control of the
combustion process and to the protection of the gas turbine hardware. Four flame detectors in separate
combustion chambers around the gas turbine are mounted to detect flame in all modes of operation. The
signals from these flame detectors are processed in control logic and used for various control and
protection functions.

XI. IGNITION SYSTEM

Two spark plugs located in different combustion chambers are used to ignite fuel flow. These spark plugs
are energized to ignite fuel during start-up only, at firing speed. Flame is propagated to those combustion
chambers without spark plugs through crossfire tubes that connect adjacent combustion chambers around
the gas turbine.

XII. CONTINGENCY OPERATION

A. Unit Trip
In the event of a unit trip, the gas fuel system will be shut down by de-energizing dump valves on the
SRV (20FGS-1) and GCVs (20FGC-1, 20FGC-2, & 20FGC-3). This action results in the isolation of
the hydraulic oil to the valves’ hydraulic cylinders while simultaneously porting any pressure in the
hydraulic cylinders to drain and the valves will be forced closed via a return spring.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 21

GEK 116535a Gas Fuel System
Figure 5. Gas Fuel Purge System
22 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
 Gas Fuel System GEK 116535a

B. False Start
During a false start, where flame is not established in the four monitored combustion chambers after
60 seconds, the Auxiliary Stop Valve, SRV, and GCVs are shut and the unit is run through a second
unit purge cycle. At the end of this purge cycle, fuel is admitted and firing is again attempted. If the
second attempt is unsuccessful in maintaining flame, the unit is tripped and the Auxiliary Stop Valve
SRV and GCVs close.

XIII. DLN-2.0+ SYSTEM ANNUNCIATOR TROUBLESHOOTING CHART

The following is a list of additional alarms and corrective actions for a gas turbine supplied with
DLN-2.0+ and related systems. This list is intended to be a supplement to the Annunciator chart
contained in the standard gas turbine operating procedures.

Alarm Message Cause Action

GAS RATIO VALVE STOP RATIO VALVE EXAMINE SRV SERVO VALVE
POSITION SERVO TROUBLE POSITION SERVO LOOP AND LVDT' FOR PROPER
TROUBLE OPERATION
GAS FUEL INTERVALVE INTERVALVE PRESSURE EXAMINE P2 PRESSURE
PRESSURE TROUBLE OUT OF LIMITS TRANSDUCERS
DIFFUSION GAS CONTROL GCV POSITION SERVO EXAMINE GCV SERVO
VLV SERVO TROUBLE LOOP TROUBLE VALVE AND LVDT' FOR
PROPER OPERATION
DIFFUSION GCV NOT GCV COMMAND SETPOINT EXAMINE GCV FOR STICKY
FOLLOWING CMD ALARM DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION LVDT TROUBLE
DIFFUSION GCV NOT GCV COMMAND SETPOINT EXAMINE GCV FOR STICKY
FOLLOWING CMD TRIP DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION FOR EXTENDED LVDT TROUBLE
PERIOD
PM4 GAS CONTROL VALVE GCV POSITION SERVO EXAMINE GCV SERVO
SERVO TROUBLE LOOP TROUBLE VALVE AND LVDT' FOR
PROPER OPERATION
PM4 GCV NOT FOLLOWING GCV COMMAND SETPOINT EXAMINE GCV FOR STICKY
CMD ALARM DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION LVDT TROUBLE
PM4 GCV NOT FOLLOWING GCV COMMAND SETPOINT EXAMINE GCV FOR STICKY
CMD TRIP DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION FOR EXTENDED LVDT TROUBLE
PERIOD
PM1 GAS CONTROL VLV GCV POSITION SERVO EXAMINE QGCV SERVO
SERVO TROUBLE LOOP TROUBLE VALVE AND LVDT' FOR
PROPER OPERATION
PM1 GCV NOT FOLLOWING GCV CMD SETPOINT EXAMINE QGCV FOR STICKY
CMD ALARM DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION LVDT TROUBLE
PM1 GCV NOT FOLLOWING GCV CMD SETPOINT EXAMINE QGCV FOR STICKY
CMD TRIP DIFFERENT FROM ACTUAL OPERATION, JAMMING AND
POSITION FOR EXTENDED LVDT TROUBLE
PERIOD
MIN PREMIX FIRING TEMP ABNORMALLY LOW LOAD RAISE LOAD TO REACH
REACHED OPERATING POINT IN PREMIX OPERATING RANGE
PREMIX MODE (TTRF1>2,200 OR 75% LOAD),
VERIFY CALCULATED
FIRING TEMPERATURE IS

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 23

GEK 116535a Gas Fuel System

Alarm Message Cause Action

CORRECT, VERIFY CPD
TRANSDUCERS, CTIM
READING, TTXM READING
NO INLET HEATING AIR LACK OF TEMPERATURE VERIFY MANUAL
FLOW DETECTED RISE AT INLET ISOLATION VALVE IS OPEN,
BELLMOUTH WITH BLEED VERIFY CONTROL VALVE
HEAT ENABLED OPERATION, CHECK INLET
THERMOCOUPLES
BLEED HEAT DRAIN VALVE IBH DRAIN VALVE STUCK INSPECT VALVE, VERIFY
FAIL TO CLOSE OR FAULTY POSITION POSITION, CHECK POSITION
FEEDBACK FEEDBACK
BLEED HEAT VALVE IBH CONTROL VALVE INSPECT VALVE, VERIFY
POSITION TROUBLE STUCK OR FAULTY POSITION, CHECK POSITION
POSITION FEEDBACK FEEDBACK
BLEED HEAT SYS NOT CONTROL VALVE STUCK OBSERVE THE CONTROL
OPERATIONAL – TRIP CLOSED OR FAULTY STROKE AND CHECK THE
INLET THERMOCOUPLE INLET THERMOCOUPLES,
READINGS, MANUAL CHECK THE MANUAL
ISOLATION/STOP VALVE ISOLATION VALVE
MAY BE CLOSED
PURGE INTERVALVE VOTED SIGNAL OF NO VERIFY PURGE FLOW,
PRESSURE LOW PRESSURE INDICATED CHECK INTERVALVE
BY THE INTERVALVE PRESSURE SWITCHES
PRESSURE SWITCHES
PURGE VLV (AIR SIDE) FAIL PURGE VALVE POSITION VERIFY VALVE POSITION,
TO LIFT OFF SEAT FEEDBACK CLOSED, LIMIT CHECK POSITION
SWITCH NOT CHANGING FEEDBACK DEVICES. CHECK
STATES IN THE ALLOTTED ACTUATION SYSTEM,
TIME CHECK ACTUATION TIME
PURGE VLV CLOSING PURGE VALVE(S) FAIL TO VERIFY VALVE POSITION,
FAULT - TRIP CLOSE CHECK POSITION
FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM,
CHECK ACTUATION TIME
PURGE VLV (AIR SIDE) PURGE VALVE FAILURE VERIFY VALVE POSITION,
FAILURE TO CLOSE TO RECEIVE CLOSED CHECK POSITION
POSITION FEEDBACK FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM
PURGE VLV (GAS SIDE) PURGE VALVE FAILURE VERIFY VALVE POSITION,
FAILURE TO CLOSE TO RECEIVE CLOSED CHECK POSITION
POSITION FEEDBACK FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM
BOTH PURGE VALVES FAIL PURGE VALVES FAILURE VERIFY VALVE POSITIONS,
TO CLOSE TO RECEIVE CLOSED CHECK POSITION
POSITION FEEDBACK FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM
PURGE VLV (AIR SIDE) PURGE VALVES OPEN VERIFY VALVE POSITION,
POSITION UNKNOWN ON AND CLOSED POSITION CHECK POSITION
CLOSE CMD FEEDBACK IN ERROR FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM,
CHECK ACTUATION TIME
PURGE VLV (GAS SIDE) PURGE VALVES OPEN VERIFY VALVE POSITION,
POSITION UNKNOWN ON AND CLOSED POSITION CHECK POSITION
CLOSE CMD FEEDBACK IN ERROR FEEDBACK DEVICES. CHECK

24 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Fuel System GEK 116535a

Alarm Message Cause Action

ACTUATION SYSTEM,
CHECK ACTUATION TIME
PURGE FAIL TO CLOSE, PURGE VALVE FAIL TO VERIFY VALVE POSITION,
INTER VLV PRESS HIGH, RECEIVE CLOSE POSITION CHECK POSITION
VENT OPEN FEEDBACK, INITIATING FEEDBACK DEVICES. CHECK
INTELLIGENT POSITION ACTUATION SYSTEM,
FEEDBACK OPERATION CHECK ACTUATION TIME
PURGE VLV (AIR SIDE) PURGE VALVES OPEN VERIFY VALVE POSITION,
POSITION UNKNOWN ON AND CLOSED POSITION CHECK POSITION
OPEN CMD FEEDBACK IN ERROR FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM,
CHECK ACTUATION TIME
PURGE VLV (GAS SIDE) PURGE VALVES OPEN VERIFY VALVE POSITION,
POSITION UNKNOWN ON AND CLOSED POSITION CHECK POSITION
OPEN CMD FEEDBACK IN ERROR FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM,
CHECK ACTUATION TIME
DRY LOW NOx-2.0+ SYSTEM DLN SYSTEM FAULT, TRIP CHECK DLN SYSTEM
TROUBLE TRIP IS REQUIRED TRIPS AND ALL OTHER
ANNUNCIATED ALARMS
DRY LOW NOx-2.0+ SYSTEM DLN SYSTEM FAULT, CHECK DLN SYSTEM
FAULT-FIRED SHUTDOWN UNSAFE TO OPERATE AT SHUTDOWNS AND ALL
CURRENT LOAD POINT OTHER ANNUNCIATED
ALARMS
PURGE VLV (GAS SIDE) FAIL PURGE VALVE POSITION VERIFY VALVE POSITION,
TO LIFT OFF SEAT FEEDBACK CLOSED LIMIT CHECK POSITION
SWITCH NOT CHANGING FEEDBACK DEVICES. CHECK
STATES IN THE ALLOTTED ACTUATION SYSTEM,
TIME CHECK ACTUATION TIME
PURGE VLV FAILURE TO PURGE VALVE POSITION VERIFY VALVE POSITION,
OPEN TO 100% FEEDBACK OPEN LIMIT CHECK POSITION
SWITCH NOT CHANGING FEEDBACK DEVICES. CHECK
STATES IN THE ALLOTTED ACTUATION SYSTEM,
TIME CHECK ACTUATION TIME
PURGE VLV OPENING PURGE VALVES FAILURE VERIFY VALVE POSITION,
FAULT - TFER TO PILOTED TO REACH FULL OPEN CHECK POSITION
PREMIX FEEDBACK DEVICES. CHECK
ACTUATION SYSTEM,
CHECK ACTUATION TIME
GAS STRAINER HIGH DP BLOCKAGE OF GAS SINGLE STRAINER
ALARM STRAINER ASSEMBLY
REPLACE STRAINER ONCE
TURBINE IS NO LONGER ON
GAS FUEL.
DUPLEX STRAINER
ASSEMBLY
CHANGE OVER TO OTHER
STRAINER. IF ALARM STILL
PRESENT, BOTH STRAINERS
NEED TO BE REPLACED.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 25

GEK 116535a Gas Fuel System

g GE Energy
General Electric Company
www.gepower.com

26 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

DLN2+ Combustion System Operation (9FA+e)
Diffusion: D5 Ignition
D5 D5

¾ Diffusion flame on all 5 nozzles D5

Diffusion
D5
¾ PM1 and PM4 manifolds purged with air
D5

Sub Piloted Premix: D5 + PM1 95% Speed

D5 D5

¾ Diffusion flame on all 5 nozzles Sub Piloted Premix

D5 D5
¾ Premix flame on PM1 nozzle
¾ PM4 manifold purged with air D5 PM1
¾ Tune D5 / PM1 split

Piloted Premix: D5 + PM1 + PM4 8% Load D5 PM4 D5 PM4

¾ Diffusion flame on all 5 nozzles D5 PM4 Piloted Premix

D5 PM4
¾ Premix flame on PM1 and PM4 nozzles
D5 PM1
¾ Tune D5 and PM1 / PM4 split

Premix: PM1 + PM4 50% Load

PM4 PM4
¾ Premix flame on PM1 and PM4 nozzles
Premix
¾ D5 manifold purged with air PM4
PM4
¾ Tune PM1 / PM4 split
PM1
 Fuel Nozzle Case
CLICK HERE
Premix Gas Supply TO VIEW
4 Nozzles - Outer Passages THE COMPLETE
COMBUSTION
Premix Gas Supply
SYSTEM
4 Nozzles - Inner Passages COMPONENT
ASSEMBLY

Premix Gas
Supply Manifold to
4 Nozzles

Fuel Nozzle
Assembly
Diffusion Gas Qty 5
Supply Manifold to
5 Nozzles
CLICK HERE
TO VIEW THE
FUEL NOZZLE
CONFIGURATION
Cover Assembly
Multi - Nozzle

Premix Gas Supply

1 Nozzle - Inner Passages
Premix Gas
Supply Manifold to
1 Nozzle Premix Gas Supply
1 Nozzle - Outer Passages
Orifice Plate

Fuel Nozzle
Cooling / Purge Air
Supply Manifold to
5 Nozzles
DLN2+ Comb 11 / 2004 © 2009 General Electric Company
DWG Number 141E7384TP Rev A Released 10/17/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 141E7384TP Rev A Released 10/17/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

 g
GEK 116445b
Revised, October 2012
Grammatical Corrections Only

GE Energy

Fuel Gas System - Gas Turbine Operational Best Practices and

Troubleshooting Guide

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

TABLE OF CONTENTS

I. INTRODUCTION ........................................................................................................................................ 4
II. COMMON ISSUES...................................................................................................................................... 4
III. STARTING RELIABILITY........................................................................................................................ 5
A. Controls................................................................................................................................................... 6
B. Operations and Maintenance .................................................................................................................. 8
C. Gas Fuel Supply.................................................................................................................................... 10
D. Fuel System .......................................................................................................................................... 10
E. On-Engine Hardware ............................................................................................................................ 13
IV. REFERENCES ........................................................................................................................................... 13

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

I. INTRODUCTION

The goal of this document is to provide a collection of troubleshooting guidance related to the operation
of gas fuel systems for gas turbines. It contains a list of common gas fuel operational issues and
troubleshooting guidelines for gas fuel start-ups. For issues concerning liquid fuel, refer to GEK 111717.

This document is generalized for E and F class units. The gas fuel system is, by its nature, a complex
system and there is significant variation in the gas fuel system depending on vintage and combustion
type. This document should not be used in place of standard troubleshooting procedures. This document
does not address the particular requirements of turbines burning heavier than air or high hydrogen fuels.

II. COMMON ISSUES

Failures in the gas fuel system come from several sources, the main categories of issues are:

● Controls: issues associated with control system, logic forcing and/or device calibration
● Gas Fuel Supply: issues associated with gas fuel supply (quality, pressure, contaminants, etc)
● Operation and Maintenance (O&M): issues associated with manual activities related to the gas fuel
system
● Fuel System: issues associated with controlling elements of the fuel system (components within the
gas module)
● On-engine Hardware: issues associated with components on the gas turbine (flame detectors, spark
plugs, fuel nozzles)

Details of the types of issues from each of the categories above are summarized in the fishbone diagram
below and discussed in following sections.

A note on fishbone diagrams:

The fishbone diagram used in this document is an illustrative overview of the more common areas of the
system / methods and should form the initial skeleton on which troubleshooting should start. It does not,
however, seek to cover every eventuality.

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without prior permission of the copyright owner.
Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

III. STARTING RELIABILITY

Fishbones are one tool used to illustrate some of the potential causes for failure modes. Not all of these
apply in every case. Contact GE for help with specific issues.

NOTE

The alarm log is a good source to start to narrow down which leg of the fishbone is
causing starting failure.

WARNING

LOGIC FORCING CAN RESULT IN UNSAFE OPERATION OF THE

GAS TURBINE. ALTERING THE FIRING TIMER, FUEL FLOW
LIMITS, ETC. ARE NOT APPROPRIATE MEANS TO ADDRESS A
UNIT THAT WILL NOT START. A PROPERLY FUNCTIONING
MACHINE WILL HAVE A HIGH STARTING RELIABILITY WITH
THE FACTORY SETTINGS. IMPLEMENT SECURITY MEASURES TO
ENSURE ONLY AUTHORIZED PERSONNEL ACCESS THE CONTROL
SYSTEM (PASSWORD PROTECT, SECURE AREA, ETC). CONTACT
GE FOR APPROVAL PRIOR TO MAKING ANY CHANGES TO
CONTROL SOFTWARE, SYSTEM HARDWARE, AND OTHER
CONTROL COMPONENTS.

Controls
O&M
Controller in maintenance Color legend
or calibration mode Air or inert gas High likelihood
Water Wash in gas piping Medium likelihood
Electrical System Issues
(system not Low likelihood
Cables disconnected
Servo valve drained properly)
calibration/null bias Valve line up
IGV angle not
Servo valve
calibrated Preventative Maintenance
contamination
Logic Forcing
(gas fuel, IGV) Calibration of
Constants spec vs.
“running” instrumentation
FSR schedule Customer / BOP / DCS
Starting
P1 or P2 pressure Failure
Fuel Lower Heating
Value and Specific transmitters
Low/Unstable Valve malfunction
Gravity in spec Flame detectors
fuel pressure
Liquid Contaminants Plugged, dirty, or Fuel nozzles
(oil, liquid Gas Leak Test Failure damaged strainer
hydrocarbones) Solid Particle
contamination Spark plugs
Gas leak into Uneven flow to cans
compartment

Gas Fuel Supply Fuel System On-engine Hardware

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

A. Controls
1. Controller in Maintenance or Calibration Mode

Check controller to determine if it has been left in maintenance or calibration mode.

2. Electrical System Issues

Load Commutated Inverter (LCI): On many units, the speed command reference to the LCI is a
milliamp signal from the control panel to the LCI. If this signal gets out of adjustment, the unit
may not exceed the minimum firing speed when brought back to firing speed after purge is
complete. If this is observed, GE should be contacted to perform the necessary adjustments.
Also, the configuration and functioning of change-over panels is critical if multiple units are
using a common LCI.

Motor Control Center (MCC): Potential for various motors / pumps to shut off, preventing
start-up (lube oil pump, cooling pump, vent fan motor, etc).

Generator: Excitation failure or issues with the Generator Protection Panel may prevent starting.

3. Cables Disconnected

Cables may have been left in disconnected state after maintenance (e.g. failure to restore system
to operational state). The alarm log is a good source to start to narrow down issues such as
disconnected cables (e.g. loose wires on LVDTs).

4. Servo Valve Calibration (Null Bias)

During the start sequence, the turbine will coast down to firing speed. The ignition sequence will
commence and fuel will be admitted to the turbine at a prescribed firing rate.

Once ignition is achieved, fuel flow will be backed down to the warm-up level for 1 minute to
allow warm-up of the hot gas path.

GCVs are open loop at light off. Any null bias error in the GCVs will tend to cause the actual
flow to lag the reference by a certain amount and this can eventually lead to insufficient fuel
flow for light off.

NOTES

i. Recommend calibration is done while the valves are hot.

ii. For systems equipped with electrically actuating SRV and GCVs refer to
section B-8 for troubleshooting guidelines specific to the electric SRV and
GCVs

There is a procedure in the A010 Control specification drawing which describes the correct
methodology for setting and checking the bias current setting on GCVs. Fundamentally, it
involves zeroing error between the command position and the feedback position.

6 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

Typically, a +0.2% error should cause the valve to slowly closed and a –0.2% error should cause
the valve to slowly open. The null bias current setting required to achieve this should be 2.67 %
or about 0.8 mA total on a new clean servo (total net current on all 3 coils). This is typical to
1kohm servos for TMR applications. It may be different for simplex and servos other than
1kohm.

Some newer units employ a null bias correction algorithm in the Mark * VI, which may reduce
effects of this issue up to a point. This does not remove the requirement to periodically check
null bias and take appropriate action.

5. IGV Angle not Calibrated

IGV angle should be the minimum angle for light off. If IGV is set at too high an angle during
light-off, there may be excess airflow through the combustor diluting fuel below the flammable
region.

6. Logic Forcing

Verify no logic points have been forced, for example: ignition output relay has been forced to off
(0).

WARNING

LOGIC FORCING CAN RESULT IN UNSAFE OPERATION OF THE

GAS TURBINE. IMPLEMENT SECURITY MEASURES TO ENSURE
ONLY AUTHORIZED PERSONNEL ACCESS THE CONTROL SYSTEM
(PASSWORD PROTECT, SECURE AREA, ETC). CONTACT GE FOR
APPROVAL PRIOR TO MAKING ANY CHANGES TO CONTROL
SOFTWARE, SYSTEM HARDWARE, AND OTHER CONTROL
COMPONENTS.

7. Constants Specification vs. Running

Check ML-A010 Control settings and specification drawing for factory specified control
constants. Compare these against the as-running controller code. Deviations need to be
understood / explained. On older units, a copy of this drawing can be requested from GE.
On most new units (post 2002 or so), the drawing should be in your manual.

8. FSR Schedule

Sometimes it is necessary to adjust some fuel stroke references to compensate for a variety of
factors. These changes should only be performed in consultation with GE Product Service.
Bypass valve null bias checks and spark plugs should always be checked first as likely causes of
failure to ignite. Excess fuel flow during ignition may cause heavy light-off and may cause
problems with the spark plugs.

*
Trademark of General Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 7
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

B. Operations and Maintenance

1. Air or inert Gas in Gas Piping

Nitrogen / Argon or other inert gases used to purge fuel systems during outages must be
thoroughly vented from the system prior to starting. Even relatively dilute concentrations may
reduce the LHV value of the fuel enough to prevent successful ignition and cross fire.

2. Water Wash (system not drained properly)

Failure to drain / dry the unit properly can result in flameout / failed ignition in one or more
combustors. It can also result in can blowouts during acceleration to FSNL. Visually verify that
all drain valves are open prior to a start and that the drain system is lined up to the appropriate
drain location (e.g. waste fuel oil tank versus waste water tank).

3. Valve Lineup

After outages or shutdowns lasting more than a few days, all manual valves should be walked
down and verified to be in the correct running position. Common causes of failure to fire include
failure to line up the 96FG-2 transmitters after calibration work and failure to open manual
valves in the gas fuel system upstream of the turbine. If no lineup procedure or checklist exists,
the turbine schematics should be printed and a site specific check list developed.

NOTES

i. It is important to ensure unit has been returned to operating condition

following Lock-out/Tag-out of any system.
4. Preventive Maintenance

Spark plugs and flame eyes should be periodically checked during downtime. Cables and flame
eye cooling tubing must be in good condition. Both sparkplugs should be free to retract from the
unit without becoming jammed in that position by one of the purge / gas lines. The unit will light
reliably with 1 spark plug operable. Therefore, there is usually little warning if one plug fails. A
simple shutdown check is to remove the DLN tuning tubing from the 2 cans and trigger the plugs
from the control system. The arc should be visible through each tuning port and an audible
clicking sound herd. A better inspection is to remove the plugs and test them.

NOTES

i. When checking operation of spark plugs, the clicking sound has previously
been mistaken for good operation by itself. If the high voltage tracks
through poor insulation or a broken porcelain fitting in the cable lead
assembly, the same characteristic click may be audible.

In addition to calibration of the stroke of the GCVs, it is also critical to review the tracking of the
GCVs with respect to reference. If the position error exceeds 0.25 to 0.50 %, the null bias current
may need adjustment. Excessive null bias adjustment may indicate a problem with the servo /
actuator or control system and should be investigated and corrected as soon as practical.

8 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

NOTES

i. For systems equipped with electrically actuating SRV and GCVs refer to
section B-8 for troubleshooting guidelines specific to the electric SRV and
GCVs
5. Servo Valve Contamination (Gas Fuel, IGV)

Hydraulic system cleanliness and correct operation is essential. Monitor all hydraulic valves for
position / flow error. Maintaining system cleanliness is vital. Hydraulic system filters should be
changed as recommended by the manual. Varnishing is a separate issue and can also cause
problems with hydraulic valves.

Gas control valves, in addition to being calibrated properly, should track their command
reference very closely typically there should be no more than 0.25 to 0.5% error. Excess error
may require adjustment of the servo current null bias or replacement of the servo valve.

NOTES

i. For systems equipped with electrically actuating SRV and GCVs refer to
section B-8 for troubleshooting guidelines specific to the electric SRV and
GCVs
6. Calibration of Instrumentation
Fuel flow during ignition, warm-up and early part of the fire sequence is, for the most part, open
loop fuel control. The flow of fuel to the combustor at light off is controlled by three critical
factors:
1. The linear stroke of the gas fuel valve(s)
2. The gas fuel pressure upstream of the control valves (P2 pressure)
3. Ambient temperature and on some units, barometric pressure.

It is therefore critical that the gas control valves (GCVs) have the correct linear stroke and that
the 96FG-2 transmitters be valved in and properly calibrated.

7. Customer / BOP / DCS

A common cause of failure to start is failure to meet Balance Of Plant / Distributed Control
System permissives. These are plant issues outside of scope of the gas turbine and are designed
to prevent starting the gas turbine when other parts of the plant are not ready (e.g. insufficient
level in steam drum).

8. Electrically Actuated GCVs and SRV

All electric SRV and GCVs are equipped with a digital valve positioner (DVP). DVPs are
programmed to recognize valve and DVP failure modes. The main failure mode is reported
through the gas turbine control system, but a complete history can be accessed by connecting to
the DVPs via the service tool software provided with the equipment.

Once the valve or DVP failure mode has been identified, refer to the component O&M Manual
for troubleshooting guidelines.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

C. Gas Fuel Supply

1. Fuel Lower Heating Value (LHV) and Specific Gravity in Spec

Monitor fuel (e.g. take fuel sample) to verify LHV, composition, specific gravity.

2. Low/Unstable Fuel Pressure

Inadequate fuel pressure or spikes in fuel pressure may result in failure to ignite.

3. Liquid Contaminants (oil, liquid hydrocarbons)

Coked nozzles from heavy hydrocarbon contamination in the gas fuel will reduce the effective
area of the nozzles and thus the firing fuel flow. Water may combine with hydrocarbon to form
hydrates which can plug instrumentation, valves, and nozzles. Determine moisture dewpoint of
gas and make sure there is adequate heating of fuel to stay above dewpoint.

Also, look for water in fuel manifolds (potentially from water wash). This may divert gas flow
from lower cans causing failure to ignite (Likely related to failure/clogging of the drain system).

4. Solid Particle Contamination

Gas fuel system cleanliness is critical during outages and installations. DLN fuel nozzle peg
holes are very small and susceptible to clogging with material left in the pipework. This includes,
but is not limited to: parts of spiral wound gasket inner rinks, purge paper and debris left behind
during welding. Make sure adequate filtration is in place (coalescing filter, etc). Suggest stainless
steel piping downstream of filter to minimize corrosion debris.

D. Fuel System
1. P1 or P2 Pressure Transmitters

Accurate measurement of gas fuel pressure is required for proper light-off. Ensure transmitters
are calibrated and reading pressure consistently.

2. Valve Malfunction

Failure to control valve position correctly can prevent light-off. Check for valve not tracking
alarms, erratic or sluggish valve response. P2 pressure overshoot is also a symptom of improper
SRV operation. Suspect valves include the Gas Control Valves (GCV), Stop/Speed Ration Valve
(SRV), Aux Stop Valve (ASV), vent valves, and purge valves.

3. Plugged, Dirty, or Damaged Strainer

Verify strainers are not clogged or damaged to ensure proper fuel flow to machine. Refer to
O&M Manual recommendations for additional guidance to address strainers.

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without prior permission of the copyright owner.
Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

4. Gas Leak Test Failure

The gas leak test gives an indication of the ability of the Gas Control Valves (GCV), Stop/Speed
Ratio Valve (SRV), and the Fuel Gas Vent Valve to shut off fuel flow to the turbine as a system.
There are multiple potential hazards that are associated with failure to isolate gas fuel:

● GCV closure and sealing capability is critical during any operational mode where one or
more fuel circuit (GCV) is open / providing fuel to the turbine and another fuel circuit
(GCV) is closed with compressor discharge air purging the piping downstream. In this
condition, excessive leakage from the GCV on the circuit being purged could result in a
flammable or explosive mixture of air and fuel gas within the fuel system piping.
● Isolating fuel from the turbine is used to bring the system to a safe state when any of a
number of potential hazardous situations are detected, such as: gas leak detection, high
vibration levels, overspeed, emergency stop push button activated, dilution ventilation
failure, excess firing fuel flow, false start drain failure, fire detection.

To mitigate these risks, GE has augmented diligent maintenance of the fuel system by
introducing an automatic gas leak test as part of the start-up sequencing. The gas leak test can
provide an indication of excessive valve leakage and prevent start-up and operation in a
potentially unsafe situation.

WARNING

LOGIC FORCING CAN RESULT IN UNSAFE OPERATION OF THE

GAS TURBINE. IMPLEMENT SECURITY MEASURES TO ENSURE
ONLY AUTHORIZED PERSONNEL ACCESS THE CONTROL SYSTEM
(PASSWORD PROTECT, SECURE AREA, ETC). DO NOT FORCE
LOGIC TO ENABLE SYSTEM START-UP IF UNIT CAN NOT PASS
GAS LEAK TEST. CONTACT GE FOR APPROVAL PRIOR TO
MAKING ANY CHANGES TO CONTROL SOFTWARE, SYSTEM
HARDWARE, AND OTHER CONTROL COMPONENTS.

NOTE

i. Because the gas leak test is done at the system level, the specific valve or
valve(s) causing failure may not be determined.

The Gas Leak Test (Bottle Test) will test the Gas Stop/Speed Ratio valve and Gas Control
Valve(s) for high leakage rates upon startup and shutdown by monitoring the pressure in the P2
cavity. The tests will take place when the turbine starts purging speed for the startup test and just
after the turbine is shutdown for the shutdown test. Once either of these enable commands have
been met, the test will start. The Gas Leak Test is composed of five steps.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 11
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

● Test A will monitor the leakage across the Stop/Speed Ratio Valve. At test start (point A),
the Auxiliary Stop valve will be commanded open (if required); the Fuel Gas Vent Solenoid
valve will be commanded shut. If the leakage across the SRV is excessive and the P2 cavity
pressure rises above the acceptable limit, turbine startup will be inhibited and the machine
will shutdown.
● Once Test A has been passed, the SRV will be commanded (point B) open briefly to ensure
the P2 cavity has been pressurized to full line (supply) pressure. The SRV and the Aux Stop
Valve (if Aux Stop Valve is present) will then be commanded closed again and Test B will
start. At this time, the P1 pressure and P2 pressure will be compared to each other. If the
difference between the two pressures is high, an alarm will notify the controller.
● Test B will monitor the P2 pressure and make sure that the Gas Control Valves or Vent
Valve are not leaking excessively. If the P2 pressure drops below the limit during Test B, the
turbine will start inhibit and latch in an alarm.
● If Test B passes, the vent will open (point D) and the pressure will drain out of the P2 cavity.
If there is no Aux stop valve, the test is over, and the turbine will proceed with normal
operation.
● If the Aux Stop Valve is present, the test will wait 5 seconds to ensure that all valves have
been returned to normal state. The SRV will then be opened again (point E) to relieve any
pressure that has been built up between that Aux Stop Valve and the SRV during the tests.
Once this pressure has been drained, the SRV will close and the test will be completed on.

NOTE

i. If the SRV does not return its normal, sealed position, when the test times
out, the P2 Pre-Ignition Trip will alarm and inhibit startup
5. Uneven Flow to Cans

Obstructions in the flow path can cause uneven flow split to the combustion cans and failure to
ignite. Check flow path for obstructions (e.g. foreign objects in manifolds or piping).

6. Gas Leak into Compartment

Check that there is no gas leaks and that the gas sensors are in calibration. Refer to GEK 28126
for further guidance on troubleshooting haz gas detection issues.

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without prior permission of the copyright owner.
Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide GEK 116445b

E. On-Engine Hardware
1. Flame Detectors

The flame detector should be inspected to ensure that the lens is clear with no signs of damage,
and the wiring should also be checked for faults. Proper insertion depth should also be verified.
If there is any doubt about the flame detector, it should be tested.

2. Fuel Nozzles

The fuel nozzle tips should be inspected to verify that all tip passages are clean and clear of any
debris. If new type fuel nozzles / liners /effusion plates or transition pieces are implemented, it
should be verified that all necessary controls changes are included. Combustion cans with spark
plug are most likely to cause a failure to ignite

3. Spark Plugs

The spark plug assembly should be inspected to verify proper insertion/retraction. The spark
plug tips should be carefully inspected for distress at the tips or damage to any of the porcelain
insulation components in either the plug or the cable from the junction box. Ignition exciter
should be verified to be leak tight and moisture free. If there is any doubt about the integrity of
the spark plugs, they should be tested.

WARNING

THE VOLTAGES USED BY THE SPARK PLUGS ARE VERY HIGH

AND MUST BE TREATED WITH APPROPRIATE CAUTION. ENSURE
ENERGY IS ISOLATED PRIOR TO ACCESSING
(LOCKOUT/TAGOUT). SPARK PLUGS ARE IGNITION SOURCES;
THEREFORE TESTING SHOULD REQUIRE A HOT WORK PERMIT.

IV. REFERENCES

GEK 111717 Dual Fuel Gas Turbine Operational Best Practices and Troubleshooting Guide – provides
guidance on liquid fuel issues.

GEK 28126 Leak Detection and Test Procedures for Fuel Gas Piping – provides guidance on response to
haz gas system issues.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 13
without prior permission of the copyright owner.
GEK 116445b Fuel Gas System - Gas Turbine Operational Best Practices and Troubleshooting Guide

g GE Energy
General Electric Company
www.ge-energy.com

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without prior permission of the copyright owner.
Tab 12
g
GEK 110832a
Revised, April 2011

GE Energy

Gas Turbine Fuel Purge System

9FA DLN 2.0+ Gas Only Unit

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
GEK 110832a Gas Turbine Fuel Purge System

This document applies to a 9FA frame size unit with the following features:

• Gas Only

I. INTRODUCTION

When burning gas in the pre-mix mode, the fuel purge system supplies active high flow purge air to the
diffusion gas manifold. During diffusion gas operation, the fuel gas purge system will provide a low flow
continuous purge to the PM4 gas manifolds to sweep unused gas out of the gas piping, manifold and
combustion end cover as well as to keep the gas piping hot to prevent condensate formation in the pipes.
When burning gas fuel in all gas manifolds, the purge system is not in operation.

II. SYSTEM OVERVIEW

The MS9001FA DLN2.0+ Gas-Only machine purges any gas manifold when fuel is not flowing through
the respective fuel gas passages. These fuel gas passages are purged with turbine compressor discharge
air. The fuel gas purge system components are shown on the schematic diagram (ML 0477).

III. SYSTEM OPERATION

A. Diffusion Gas Purge
When the gas turbine is operating burning natural gas in the pre-mix mode, the diffusion gas purge
system receives air from the discharge of the gas turbine compressor. This purging air flows through
two fuel gas purge valves (VA13-1 & 2) to the diffusion gas primary manifold. All the components
described in this system will be located in the Accessory Module.

For the diffusion gas purge system, fuel gas purge valve VA13-1 is controlled by allowing instrument
air to flow through quick exhaust valve VA36-1. The quick exhaust valve is opened by the associated
solenoid valve 20PG-1. When the solenoid valve is energized, instrument air pilots the gas purge
valve to the open position allowing air to flow to first the fuel gas purge valve VA13-2 and then to
the natural gas manifold.

Fuel gas purge valve VA13-2 is controlled by allowing instrument air to flow through quick exhaust
valveVA36-2. The quick exhaust valve is opened by the associated solenoid valve 20PG-2. The
amount of instrument air flowing to the actuator of gas fuel purge valve VA13-2 is regulated by a 4-
20mA electro-pneumatic positioner, 65EP-G1P. Pressure regulator VPR54-22 limits the maximum
instrument air pressure allowed to pass through 65EP-G1P.

The rate of opening of purge valve VA13-1 is manually controlled by needle metering valves located
downstream of solenoid valve 20PG-1. The turbine control panel shall control the opening of purge
valve VA13-2. The opening time of these purge valves shall be set in accordance with the
requirements on the schematic diagram (MLI 0477). Limit switches (33PG-1, 2) indicate the
open/closed position of fuel gas purge valve VA13-1. Limit switch 33PG-3 indicates that valve
VA13-2 is fully closed and limit switches 33PG-4A, 4B indicate when the valve is partially open. See
the device summary for the set points of 33PG-4A, 4B.

A vent valve VA13-8 is located between these two purge valves which provides a block and bleed
system. Should the leakage past the gas purge valves in either direction become too excessive for the
vent valve to bleed off, pressure switches 63PG-1A, 1B, 1C will sense the cavity pressure and result
in the turbine control system taking appropriate action should the predetermined pressure set point
breached.

2 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

 Gas Turbine Fuel Purge System GEK 110832a

Three thermocouples (dual element type with one spare), PT-G1-1A,1B,2A,2B,3A,3B are located at
the bottom of the diffusion gas fuel manifold. While operating diffusion purge, the turbine control
panel ensures that the purge air temperature is above air saturation temperature, via these
thermocouples, in order to avoid condensate formation.

B. PM4 Gas Purge

When the gas turbine is burning natural gas in the diffusion mode, the PM4 gas purge system
receives air from the discharge of the gas turbine compressor. This purging air flows through fuel gas
purge valves VA13-5, 6 (PM4) to the corresponding natural gas manifold. All the components
described in this system will be located in the Accessory Module.

For the PM4 gas purge systems, each fuel gas purge valve is controlled by allowing instrument air to
flow through the associated actuator quick exhaust valves VA36-9,10 (PM4). The quick exhaust
valves are opened by the associated solenoid valves 20PG-5,6 (PM4). When the solenoid valves are
energized, pilot air is supplied to the quick exhaust valves which opens them and allows instrument
air to flow to the gas purge valves causing them to open and allowing air to flow to the corresponding
natural gas manifold(s). Valve actuating air is supplied from customer supplied or a separate
instrument air source. The rate of opening of these purge valves is manually controlled by needle
metering valves located just upstream of the quick exhaust valves, VA36-9, 10 (PM4). The opening
time of these purge valves shall be set in accordance with the requirements on the schematic diagram
(MLI 0477). Limit switches 33PG-9T12 (for PM4) indicate the position of each fuel gas purge valve.

A vent valve VA13-13 (for PM4), is located between each set of these purge valves which provides a
block and bleed system. Should the leakage past the gas purge valves in either direction become too
excessive for the vent valve to bleed off, pressure switches 63PG-3A, 3B, 3C for (PM4) will sense
the cavity pressure and result in the turbine control system taking appropriate action should the
predetermined pressure set point be reached.

The PM4 gas purge systems will functionally operate exactly the same way as the diffusion gas purge
system with the exception that a flow regulating orifice will be utilized to provide a low flow
continuous sweep of the PM4 gas piping and manifolds during liquid fuel operation.

C. Routing of Vent Lines by Customer/Installer

PG1, and PG13 are potential Class 1 Div 1 sources of natural gas. Installer shall route these lines
separate from other vents, to a naturally ventilated area outside of any buildings or enclosures, and in
an area free from sources of ignition. The extent of the hazardous area created by PG1 and PG13 is a
5 ft Class I, Div 1, Group D spherical radius and an area between 5 ft and 10 ft is considered to be a
Class I, Div 2, Group D spherical radius.

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved. 3

GEK 110832a Gas Turbine Fuel Purge System

g GE Energy
General Electric Company
www.gepower.com

4 © General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4554 Rev - Released 10/26/2012 Page 1 of 2

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GE Proprietary Information - Class II (Internal) US EAR - NLR
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GE Proprietary Information - Class II (Internal) US EAR - NLR
Tab 13
g
GEK 116682
August 2010

GE Energy

7FA/9FA Cooling and Sealing Air System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 116682 7FA/9FA Cooling and Sealing Air System

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

TABLE OF CONTENTS

I. GENERAL...................................................................................................................................... 4

II. FUNCTIONAL DESCRIPTION .................................................................................................. 5

A. Compressor Bleed Subsystem For Pulsation Protection.......................................................... 5
B. Turbine Nozzle Cooling Air Supply Subsystem ...................................................................... 6
C. Exhaust Frame and No. 2 Bearing Area Cooling Fan Module Subsystem.............................. 7
D. Exhaust Temperature Reference Bias Substation .................................................................... 7
E. Case Temperature Management (CTM) Clearance Control System........................................ 8

III. OTHER SYSTEM FEATURES ................................................................................................... 13

A. Pressurized Air Supply ............................................................................................................ 13
B. Water Wash Provisions ............................................................................................................ 13

LIST OF FIGURES

Figure 1. Case Temperature Management (Clearance Control System) Top Level Summary Diagram ... 10
Figure 2. 7F Case Temperature Management (Clearance Control System) Manifold Detail ................. 10
Figure 3. 9F Case Temperature Management (Clearance Control System) Manifold Detail ................. 11

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 116682 7FA/9FA Cooling and Sealing Air System

I. GENERAL

The cooling and sealing air system provides the necessary air flow from the gas turbine compressor to other
parts of the gas turbine rotor and stator. These flows prevent excessive temperature buildup during normal
operation and prevent compressor pulsation. The system also has a Case Temperature Management (CTM)
Clearance Control System, which utilizes impingement air cooling to reduce and control the temperature
of the turbine casing at and around the area of the first turbine stage. The result of this cooling process
is a reduction in the nominal clearances between the tips of the turbine stage 1 blades (buckets) and their
associated casing shrouds. This reduction in clearance decreases the leakage past the blade tips, resulting
in improved turbine performance. In addition to reducing clearances, the impingement cooling process
decreases ovality of the turbine casing, which also improves performance. Activation and operation of the
system is limited to gas turbine loads above 60% of baseload operation.

The 7FA & 9FA turbines have a vacuum-operated lubrication system. Therefore, the bearing sealing func-
tion of the Cooling & Sealing Air System is not utilized. When the gas turbine is operating, air is extracted
from the 9th and 13th stages of the axial flow compressor as well as from the compressor discharge.

Atmospheric air from off-base, centrifugal-type, blowers is used to cool the turbine exhaust frame and No.
2 bearing area.

Cooling functions provided by the system are as follows:

1. Compressor pulsation protection

2. Internal component cooling

3. Turbine exhaust frame cooling

4. No. 2 bearing area cooling

5. Case Temperature Management (CTM) Clearance Control

The cooling and sealing air system consists of specially designed air passages in the turbine casing, turbine
nozzles, rotating wheels, and piping for the compressor extraction air and associated components.

Components used in the system include:

1. Turbine Exhaust Frame Cooling Blowers

2. Motors for Turbine Exhaust Frame Cooling Blowers (88TK-1, -2)

3. Pressure switches for Turbine Exhaust Frame Cooling Blowers (63TK-1, -2)

4. Backdraft damper for Turbine Exhaust Frame Cooling Blowers (VCK7-1)

5. No. 2 Bearing Area Blowers

6. Motors for No. 2 Bearing Area Blowers (88BN-1, -2)

7. Pressure switches for No. 2 Bearing Area Blowers (63BN-l,-2)

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

8. Air filters for No 2 Bearing Area Blowers

9. Backdraft damper for No 2 Bearing Area Blowers (VCK7-3)

10. Air Extraction Valves VA2 -1, -2, -3, -4

11. Limit switches for each VA2 valve 33CB-1, -2, -3, -4,-5,-6,-7,-8.

12. Solenoid Valves 2OCB-1, -2 (for actuation of air extraction valves)

13. Compressor Discharge Pressure Transducers 96CD-1, -1B, and -1C

14. Case Temp. Management Blower Motor and Blower Motor Space Heater (88CM-1 & 23CM-1)

15. Case Temp. Management Flow Control Damper (20CM-1)

16. Case Temp. Management Flow Control Damper Positioner (65CM-1)

17. Case Temp. Management Air Supply Temp. Trans. (TT-CM-1)

18. Case Temp. Management Air Supply Pressure Transmitter (96-CM-1)

19. Turbine Casing Thermocouple - 1st Stage Shroud (TT-TC-1 to 16)

Refer to the cooling and sealing air schematic diagram MLI 0417 for further details.

II. FUNCTIONAL DESCRIPTION

The cooling air system is composed of five major subsystems:

1. Compressor bleed subsystem for pulsation protection

2. Turbine nozzle cooling air supply subsystem

3. Exhaust frame and No. 2 bearing area cooling fan module subsystem

4. Exhaust temperature reference bias subsystem

5. Case Temperature Management (CTM) Clearance Control System

A. Compressor Bleed Subsystem For Pulsation Protection

The pressure, speed, and flow characteristics of the gas turbine axial flow compressor are such that
special equipment and sequencing of the gas turbine components are required to prevent pulsation
of the compressor when the turbine is fired and when accelerating to speed in the starting sequence.
Pulsation protection is also required in the shutdown and decelerating sequence when the turbine is
tripped. The equipment required to provide this protection is the compressor bleed valve subsystem
and the variable inlet guide vane subsystem. The operation of the inlet guide vane subsystem is covered
elsewhere in this manual.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

GEK 116682 7FA/9FA Cooling and Sealing Air System

The 7FA+e is fitted with four pneumatically closing butterfly valves (VA2-1, -2, -3, -4) to bleed 9th
and 13th stage compressor air to the exhaust. These valves utilize a spring to open, so a failure in the
actuation air system will cause the valve to move to the open position, placing the compressor in a safe
mode for shutdown.

Customer supplied instrument air (controlled by solenoid valves 20CB-1,-2) is used to close the com-
pressor bleed valves. From each solenoid valve, the air is piped to the piston housings of 2 bleed valves.

The 20CB solenoids are fitted with a breather vent which should be inspected as well to ensure that
air can freely flow from the “C” port of the solenoid to the atmosphere. If this breather is clogged, the
valves will not open in a timely manner, and the turbine may experience a trip.

During turbine startup, 20CB-1, -2, are not energized and the 9th and 13th stage bleed valves are open,
allowing air to be discharged into the exhaust plenum, thereby eliminating the possibility of compressor
pulsation. Limit switches, 33CB-1, -2, -3, -4, on the valves provide permissive logic in the starting
sequence and ensure that the bleed valves are fully opened before the turbine is fired. The switches also
provide an alarm if either valve opens when it is supposed to be closed. When the turbine accelerates
to full speed, the 20CB-1, -2, solenoid valves energize to close the bleed valves and allow normal
running operation of the turbine. Limit switches 33CB-5, -6, -7, and -8 are used to detect that the
valves are closed. When a turbine shutdown signal is initiated, the 20CB-1, -2 valves are de-energized,
and compressor air is again discharged into the exhaust plenum to prevent compressor pulsation during
the turbine deceleration period.

CAUTION

Under no circumstances should attempts be made to start the turbine if all bleed
valves are not fully opened. Serious damage to the gas turbine may occur if valves
are not opened during the accelerating and decelerating cycle of the turbine.

Although the bleed valves appear to be in a parallel redundant arrangement, they are not redundant.

Both valves are required to function to provide adequate pulsation protection.

B. Turbine Nozzle Cooling Air Supply Subsystem

The cooling circuit for the turbine components consists of both internal and external circuits. The
first and second stage buckets, the first stage nozzle, and the first stage shroud are cooled by an internal
cooling air circuit, while the second and third stage nozzles are cooled by an external cooling air circuit.

The internal circuit is supplied by 17th stage and compressor discharge air, and the external circuit
by 9th and 13th-stage extraction air. The first stage nozzle and shroud cooling air is supplied from the
compressor discharge plenum housing the combustion transition pieces. The bucket cooling is supplied
by air flowing inward at the 17th-stage compressor wheel, then through holes drilled axially through
the distance piece, and then over the forward face of the first stage turbine wheel. The bucket cooling
air then flows through the bore of the first stage turbine wheel into the chamber between the first and
second stage buckets. This circuit also provides air to heat the bores of the second- and third stage
wheels and to purge the wheel spaces.

The external circuit consists of piping between the 9th and 13th-stage bleed piping and the turbine
shell. A two branch piping system is used to pipe the cooling air from the compressor 13th-stage to the
stage 2 turbine shell. 9th stage compressor extraction is used to cool turbine stage 3.

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

This subsystem piping is shared with the compressor bleed subsystem to minimize piping quantity.
In each piping run to the second-stage nozzle, a witch-hat strainer is placed in the pipe to protect the
small impingement cooling holes within the vanes from clogging with dirt and scale. These witch-hat
strainers are removed after an initial break-in period. The orifice plates in the pipe runs to each nozzle
control the airflow throughout the piping system.

C. Exhaust Frame and No. 2 Bearing Area Cooling Fan Module Subsystem

A cooling fan module consisting of four centrifugal blower-driven motors 88TK-1, -2 and 88BN-1, -
2 provides airflow to the exhaust frame cooling manifold and the No. 2 bearing area. Each blower is
sized to provide 100 percent of the required flow for its respective cooling requirement. The motors
are controlled to operate in a lead-lag arrangement so that only one of each blower is operating when
the gas turbine is running. Each motor is equipped with a space heater, 23TK -1, -2 or 23BN-1, -2, for
humidity control during periods of shutdown.

Two of the blowers supply air for cooling of the exhaust frame and third aft wheel space. An inlet
screen is provided with each blower and the discharge of each passes through a diverter type check
valve VCK7-1 before entering openings in the exhaust frame. The cooling air enters the exhaust frame
through eight radial nozzles on the outer annulus of the frame. The air cools the outer diameter of the
outer exhaust gas path insulation pack. Some of the cooling air exits the frame at the forward joint with
the third stage bucket shroud. The remainder flows aft, then turns, flowing through and cooling the
radial support struts. The air cools the inner diameter of the inner exhaust gas path insulation pack and
exits the exhaust frame through the third stage bucket aft wheel space. The cooling air also prevents
exhaust gas from being aspirated into the No. 2 bearing sump.

A similar arrangement of two blowers is used to provide cooling air to the No. 2 bearing area. These
arc equipped with inlet filters to remove dirt particles that could harm the bearing journal. Also, the
discharge of each passes through a diverter type check valve VCK7-3 before entering the main supply
pipe to the No. 2 bearing area. This valve is required because of the lead-lag operation; otherwise the
air from the operating blower would escape through the non-operating blower, thereby bypassing the
cooling circuit.

Pressure switches 63TK-l and -2 on the exhaust frame blowers, and 63BN-l and 63BN-2 on the No.
2 bearing area blowers are used to sense each of the blower’s discharge pressure. If either blower or
motor in the operating set should fail, the loss of discharge pressure will cause contacts of the respective
63TK or 63BN pressure switch to close, sending a signal to start the idle set. If a second failure should
occur, the turbine will shut down in a normal shutdown sequence.

NOTE

Any failed blower or motor should be repaired or replaced as soon as possible to

preclude the possibility of shutting down the turbine as a result of a second failure.

D. Exhaust Temperature Reference Bias Substation

Turbine firing temperature limits are determined primarily by turbine parts’ lives. To obtain the most
cost-efficient operation of the gas turbine, in electric generation service it is customary to operate the
gas turbine at the turbine firing temperature limit. The turbine control system makes a calculation of
the actual firing temperature and controls operation of the turbine so that the firing temperature limit is
not exceeded by the calculated/actual firing temperature.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116682 7FA/9FA Cooling and Sealing Air System

The firing temperature is calculated from three inputs: the average thermocouple measured exhaust
temperature, the actual pressure ratio across the compressor, and mechanical parameters of the turbine.

If the 96CD compressor discharge pressure transducers and their associated electronics should fail, the
control system also permits the calculation of firing temperature based on exhaust temperature and the
actual fuel consumption.

E. Case Temperature Management (CTM) Clearance Control System

The following paragraphs provide a detailed description of the CTM System Equipment. Figure 1 is a
schematic representation of the system.

1. Case Temperature Management Blower Skid

The Case Temperature Management (CTM) Blower Skid is located outdoors adjacent to the tur-
bine enclosure. It’s exact location is site specific and is based on the plant’s general arrangement.
The Skid consists of a single speed Centrifugal Blower, a pneumatically actuated Discharge Flow
Control Damper/Valve, and Instrumentation (including temperature measurement and a Back-
draft Damper/Check Valve at the outlet of the Skid).

The Blower Unit is furnished with a Filtration System at the inlet to the suction stack. This min-
imizes the erosion wear on the blower wheel, and prevents large particulate from entering and
potentially “plugging” the impingement cooling holes of CTM manifolds. The Filters require
periodic monitoring for cleaning or replacement. The frequency is dependent on the cleanliness
of the environment. In addition to the filtration system, the blower suction stack also houses
inlet Silencing Panels. This silencing is provided to maintain the Blower’s acoustic levels be-
low site specific limits. The centrifugal blower is driven by a single speed 3-phase TEFC Motor
(88CM-1). Starting and stopping of the Blower is through the turbine control system. For 7F
frames a 120V Space Heater (23CM-1) is provided for the prevention of condensate in the motor
when the system is not in operation. Similarly on the 9F frames, a 220V, 50Hz space heater is
provided.

A pneumatically actuated butterfly “style” Flow Control Damper/Valve (20CM-1) is located at the
discharge of the blower. The actuator is furnished with a I/P Positioner (65CM-1) that controls the
position of the valve based on the airflow demand to the system. The command to the positioner is
from the turbine control system. The actuator is furnished with a Mechanical Stop that prevents
its full closure of the valve. This insures the Blower operates at or above it’s minimum flow
condition when the CTM system is enabled.

A Temperature Transmitter (TT-CM-1) and a Pressure Transmitter (96CM-1) are located in the
skid piping, directly downstream of the flow control valve/damper. The temperature transmitter
provides a signal to the turbine control system for the monitoring of the impingement cooling air
temperature. This temperature signal is used in permissive logic that prevents the system from
operating with cooling air temperatures below the minimum allowable. The pressure transmitter
provides a signal to the turbine control system for the monitoring of the CTM cooling air pressure.

A backdraft damper/check valve is provided at the outlet of the skid. This remains closed at all
times when the Gas Turbine is not in operation and the turbine compartment ventilation system
is turned off. The function of the damper/check valve is to maintain isolation of the turbine com-
partment during the release of CO2 following afire detection event.

8 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

2. On-Base Piping System

The On-Base piping system is the CTM piping located within the bounds of the gas turbine pack-
age. The primary function of this piping is to evenly distribute the cooling air to the eight indi-
vidual impingement cooling manifolds. The main pipe header and the left and right side “feed”
headers are constructed of hard pipe. A flow balancing orifice is installed in the main pipe header
between the left and right side feed headers. This is provided to maintain equalized pressure/flow
to the manifolds on each side of the turbine. Flex ducting is utilized to interconnect the air supply
from the feed headers to the inlet pipes on the manifolds.

3. CTM Impingement Cooling Manifolds

Eight (8) Impingement Cooling Manifolds are utilized in the CTM system. Each manifold as-
sembly consists of a feed pipe, a “sealed” plenum box, and leveling legs (See Figures 2, 3). The
size and geometry of the manifolds vary between the 7F and 9F frames. A graphical represen-
tation of this is shown in Figures 2 and 3. The bottom, or innermost, plate of the box has an
array of impingement cooling holes over the entire surface area. The position and size of these
holes provide uniform cooling of the turbine casing over all CTM system operating modes. The
plenum box is contoured to the geometry of the casing surface that the manifolds are mounted
over. This insures a uniform gap between the manifold inner plate and the below casing surface.
Each manifold is affixed to the turbine casing by two integrated support/thermowell mounting
assemblies. These (shaft) assemblies feed throughout the inner and outer surfaces of the plenum
box thread into tapped holes in the turbine casing. In addition to their mounting purpose, these
supports also function as thermowells for the embedded casing TCs (see paragraph E.) Six (6)
adjustable leveling legs are positioned around the perimeter if each manifold. These provide the
desired gap clearances from the manifold to the casing surface.

4. Embedded Casing Thermocouples

Sixteen (16) Embedded Casing Thermocouples (TT-TC-1 to 16) are located in the turbine casing,
directly below the CTM manifolds. Of the sixteen TCs, twelve are positioned “deep” (relatively
close to the stage 1 shroud) and four are positioned “shallow” (relatively close to the casing sur-
face). These instruments are utilized to monitor casing temperatures and thermal gradients prior to
and during CTM system operation. Readings from these instruments provide input to the closed
loop control sequencing that regulates the amount of cooling air required to achieve the target
clearance reduction.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 9

GEK 116682 7FA/9FA Cooling and Sealing Air System

Figure 1. Case Temperature Management (Clearance Control System) Top Level Summary
Diagram

Figure 2. 7F Case Temperature Management (Clearance Control System) Manifold Detail

10 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

Figure 3. 9F Case Temperature Management (Clearance Control System) Manifold Detail

SYSTEM OPERATION

1. CTM System Start-Up

All control and operation of the Case Temperature Management (CTM) Clearance Control Sys-
tem is performed through the gas turbine control system. Initiation and operation of the CTM
system is limited to GT loads at or above approximately 60% of rated baseload. Activation of the
system can occur only when casing thermals (temperatures) achieve a “steady state” condition.
Internal casing temperatures are monitored by the sixteen embedded thermocouples (TT-TC-1 to
16), which are located directly below the CTM manifolds. In general, steady state temperatures
are achieved following 10 minutes of constant load operation.

Once all permissives are cleared, an enable to START indication is provided on the turbine con-
trol system HMI screen. Starting of the system is a manual operation performed by the control
room operator. Casing temperatures and cooling air supply pressure and temperatures should be
monitored during system start-up.

2. CTM System Operation - Gas Turbine Steady State Operation

During steady state gas turbine operation, the CTM system utilizes closed loop control to maintain
target stage 1 clearances. As cycle conditions change due to minor load or ambient temperature
variations, impingement cooling airflow is regulated by automatic modulation of the case tem-
perature management flow control valve/damper.

3. CTM System Operation – Gas Turbine Transient Operation

If, during CTM operation, there is a significant change in gas turbine load (step or ramp), the CTM
system will become disabled. Following this transient event, the Flow Control Valve/Damper
(20CM-1) is commanded to the minimum flow stroke position and is maintained in “standby”
mode. Once the load and casing temperatures are stabilized, as sensed by the Embedded Casing

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 11

GEK 116682 7FA/9FA Cooling and Sealing Air System

Thermocouples (TT-TC-1 to 16), the system is re-enabled. At this time the Operator is required
to manually activate the system to achieve clearance control operation.

4. CTM System Shutdown

The CTM system can be manually shut down at any time during normal steady state operation, or
while in “standby” mode following gas turbine transient/CTM disable event. It is recommended,
but not a requirement, to turn off the CTM system prior to unloading the turbine in preparation
for a gas turbine shut down.

5. CTM System Lockout and Faults

The CTM controls includes the following Lockouts and Faults that will a automatically disable
or prevent activation of the system:

• High Casing Gradient Temperature

• One Shallow TC Fault

• Low Manifold Air Temperature (Due to low ambient temperatures)

• High turbine Vibrations

• High Turbine Compartment Temperature

• Turbine Trip/Load Rejection/Shutdown

• Uneven Quadrant Cooling

• Blower Fault

TECHNICAL DATA

1. Maintaining System Performance Following GT Maintenance

Many CTM components will need to be removed during standard gas turbine maintenance. These
include the CTM Manifolds, On-Base Piping System and Embedded Casing Thermocouples and
associated conduit and wiring. It is critical that the following areas are addressed when re-assem-
bling the CTM system components following their removal:

a. CTM manifolds properly secured on the turbine casing with ¾” gaps maintained. All inte-
grated support/thermowell mounts shall be fully (thread engaged) in the casing and leveling
support nuts “snug” against the casing surface.

b. Embedded casing TC’s shall be inspected for damage prior to reinstallation. When inserted, it
shall be confirmed that the fittings are fully engaged in the support/thermowell mount. Loop
checks shall be performed on any TC’s removed and/or replaced.

c. The flexible metal ducting shall be inspected for damage that could impact airflow. If dam-
aged, the ducting section shall be replaced with new part. All T-bolt clamps used to connect

12 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

7FA/9FA Cooling and Sealing Air System GEK 116682

ducting to hard pipe interfaces (on manifolds an on piping) shall be inspected to insure they
are tight.

III. OTHER SYSTEM FEATURES

A. Pressurized Air Supply

Compressor discharge air is used as a source of air for operating various air-operated valves in other
systems. Air for this purpose is taken at the discharge of the compressor and is then piped to the various
air-operated valves. In addition, compressor discharge pressure is monitored by pressure transducers
96CD-I, 96CD-1B, & 96CD-1C for use in control of the gas turbine.

B. Water Wash Provisions

When water washing the gas turbine’s compressor or turbine section, it is important to keep water out
of components not intended to be washed.

During normal operation of the gas turbine, all drain valves are to be closed. Before initiating water
wash, the drain valves must be opened. At the conclusion of the water wash, the drain valves must be
closed to allow normal operation of the turbine.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 13

GEK 116682 7FA/9FA Cooling and Sealing Air System

g
GE Energy
General Electric Company
www.gepower.com

14 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4548 Rev - Released 10/25/2012 Page 1 of 4

SIZE DWG. NO. SH. REV.

E 1 -
REVISIONS
THIS DOCUMENT SHALL BE
NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT
ARE THE SAME REVISION
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION LEVEL AS INDICATED.
INCLUDED IN MLI 0438 APPLY.
3. THE TERM “OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT
DESIGNER AND/OR PLANT INSTALLER.
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE
CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH “PC” ARE
GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
5. GE RECOMMENDS HEAT TRACING FOR FREEZE PROTECTION (BY OTHERS) TO
ALL EQUIPMENT THAT MAY EXPERIENCE CONDENSATION ACCUMULATION, IF
MINIMUM AMBIENT TEMPERATURE IS BELOW 40F (4C). IT IS THE RESPONSIBILITY
OF OTHERS TO IMPLEMENT ALTERNATE FREEZE PROTECTION IF HEAT TRACING
IS NOT CONSIDERED.
6. ALL LINE LOCATIONS ARE FOR REFERENCE ONLY, NOT INTENDED TO DEPICT
TRUE LOCATION ON CASING.
7. TEMPORARY, CONICAL "WITCH HAT" STRAINERS AND PRESSURE GAUGES
USED FOR START UP AND MAINTENANCE. REFER TO ML ITEM A179 FOR
HARDWARE AND INSTRUCTIONS.
8. ALL PLUG LOCATIONS ARE FOR ILLUSTRATIVE PURPOSES ONLY. TRUE
LOCATIONS MUST BE DETERMINED FROM ASSOCIATED ARRANGEMENT
DRAWINGS.
9. N/A
10. N/A
11. THESE ARE INTERNAL GEE-GEE INTERFACES. ALL PIPING, EQUIPMENT AND
PROCESS CONDITIONS ARE IN GEE SCOPE.
12. LINE CONNECTS TO PORT MARKED “S” (AIR SUPPLY) ON VALVE.
13. LINE CONNECTS TO PORT MARKED “I” (SIGNAL AIR) ON VALVE.

1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671

IT. NOMENCLATURE IDENT
LIST OF COMPLEMENTARY DOCUMENTS
GE CLASS II (INTERNAL NON-CRITICAL)
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY
© COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. DIMENSIONS ARE IN INCHES
DRAWN
CANDELARIA, ARNOLD 12-09-27
g GE Energy GAS TURBINE

ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE ENERGY GAS TOLERANCES ON CHECKED

2 PL DECIMALS ± SEE PLM 12-09-27

TURBINE PROPRIETARY TECHNICAL INFORMATION THAT BELONGS TO THE GENERAL 3 PL DECIMALS ± ENGRG
LAMAR, CARL 12-09-27
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR THEIR AFFILIATES, WHICH HAS ANGLES ±
FRACTIONS ± ISSUED
SEE PLM 12-09-27
DIAG, SCHEM PP-CLG & SLG
BEEN PROVIDED SOLELY FOR THE EXPRESS REASON OF RESTRICTED PRIVATE USE.
QUALITY
ALL PERSONS, FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL
BE DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED TO MAKE FIRST MADE FOR: ML-9K1WFA163-1 0417
THIRD ANGLE PROJECTION
NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER FOR ANY, OR ALL SIZE CAGE CODE DWG NO

SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY THE GENERAL

DISTR
ELECTRIC COMPANY, GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. SIM TO:

TO
NONE SCALE SHEET 1 of 4

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 145E4548 Rev - Released 10/25/2012 Page 2 of 4

SIZE DWG. NO. SH. REV.

E 2 -

SEE NOTE 5

Ø 7.31
ZS ZS
[186 MM]
33CB-1 33CB-5

SEE NOTE 11
VA2-1
TO MLI 0471,
INLET & EXHAUST
FO
NO
COMP BLEED EXTRACTION 1022 SEE NOTE 5

INSTRUMENT AIR
“BY OTHERS”
NO
Ø 7.44
SEE NOTE 8 [189 MM]

TO MLI 0477,FUEL
ZS ZS

PURGE, “PG29”
33CB-3 33CB-7

SEE NOTE 11 PC
VA2-3
TO MLI 0471, CA60A
0909 0909 INLET & EXHAUST
FO

AD-6
COMP BLEED SOLENOID 1071
COMP BLEED EXTRACTION 1022 INSTRUMENT AIR A C
“BY OTHERS”
20CB-1
PC PC
NO CA54 CA60B B

NC COMP BLEED SOLENOID 1071

A C

20CB-2
B

0924

TO SHEET 3 AD-5A Ø 1.96

ZONE F-5, “A” [49.7 MM]
TT TO SHEET 3 AD-5B 0972
ZONE F-5, “B” FROM SHEET 3
TT-S13-1 0637
ZONE H-4, “D”
TO SHEET 3 AD-5C
ZONE F-5, “C” TT
TT PC
TT-S2Q-3
NC CA52A
TT-S9-1

0637 AD-4A
AE-9 PC
AE-13 NC CA53A AD-4B
AD-4C

NO.1 NO.2
COMPRESSOR TURBINE
BRG BRG

NO. 2 BEARING
AREA

PC AD-2
AE-13
CA53B AD-1
AE-9 PC
CA52B

ZONE C-7, “AD-9A”

ZONE B-7, “AD-9B”

NC

TO SHEET 4

TO SHEET 4
NC
0972
0972
FROM SHEET 3
TT ZONE F-4, “E”
ZONE C-5, “AE-13A”

ZONE A-5, “AE-13C”

ZONE B-5, “AE-13B”
TO SHEET 4

TO SHEET 4

TO SHEET 4

AD-3 TT-S2Q-4

TO MLI 0419, 0637

CONTROL AIR, “AP1” Ø 1.96
PC NO [49.7 MM]
0909 0909 0924 PC 0909
CA5 0924
1097 CA16
TO MLI 0432, INLET
AIR HEATING, “IH3”
NC
PC
CA20 SEE NOTE 5
ZONE C-4, “AE-9A”

ZONE A-4, “AE-9C”

ZONE B-4, “AE-9B”
TO SHEET 4

TO SHEET 4

TO SHEET 4

ZS ZS
33CB-4 33CB-8

VA7-3
0637
SEE NOTE 11
FC
FROM SHEET 4
ZONE G-3, “AD-5J”
SEE NOTE 12

ZS TT VA2-4 TO MLI 0471, INLET

BYPASS- SEE & EXHAUST
33-TQ2-5A TT-S2Q-2 FO
MIXER NOTE 7 Ø 7.44 0909
ZS [189 MM] COMP BLEED EXTRACTION 1022
ZS
33-TQ2-4
33-TQ2-5B
ZS SEE NOTE 5
ZS
33-TQ2-3
33-TQ2-5C
1022
VA7-2 SEE NOTE 13 SEE NOTE 12 ZS ZS
FO
FROM SHEET 4 FROM SHEET 4
ZONE E-3 “AD-5I” ZONE F-3, “AD-5H” 33CB-2 33CB-6
ZS
33-TQ2-2 NO
NO
SEE NOTE 11
ZONE G-3, “AD-5K”
FROM SHEET 4

1022 VA2-2 TO MLI 0471,

INLET & EXHAUST
FO
SEE NOTE 13

Ø 7.31
[186 MM] COMP BLEED EXTRACTION 1022 GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy

DISTR
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CANDELARIA, ARNOLD

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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 145E4548 Rev - Released 10/25/2012 Page 3 of 4

SIZE DWG. NO. SH. REV.

E 3 -

TO SHEET 2
ZONE E-3, “D” CA71

PT
96CD-1C

ATM ATM
NC
PT PT
VCK7-1
96CD-1B 96CD-1 PS PS
M M
63TK-1 63TK-2
NO NC NC 88TK-1 88TK-2
23TK-1 23TK-2

AD-5C
NO NO

FILTER
AD-5C
AD-5B AD-5A ATM

CA12A VCK7-3
AD-5A FROM SHEET 2
ZONE E-6, “A”

CA12B M M
AD-5B FROM SHEET 2 PS PS
ZONE E-6, “B” 88BN-1 88BN-2
63BN-1 63BN-2
23BN-1 23BN-2
CA12C
AD-5C FROM SHEET 2
ZONE E-6, “C” COOLING FAN MODULE A132

CA72
TO SHEET 2
PRESSURE TRANSDUCER ARR. 557T ZONE C-2, “E”

GE CLASS II (INTERNAL NON-CRITICAL)

GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy

DISTR
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CANDELARIA, ARNOLD

TO
ISSUED
SEE PLM
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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 145E4548 Rev - Released 10/25/2012 Page 4 of 4

SIZE DWG. NO. SH. REV.

E 4 -

INSTRUMENT AIR
“BY OTHERS”
PC
CC3

65CM-1
88CM-1
M I
23CM-1 TT PT
P ZT
CA79A
TT-CM-1 96CM-1
96CM-2
TO SHEET 2 I
FC 65EP-18
ZONE A-8, “AD-5K” P
ATM
20CM-1

VPR17-4 PC
CA64
1
S 20-TQ2-2
CA79C 3 INSTRUMENT AIR
2 “BY OTHERS”
TO SHEET 2
ZONE B-8, “AD-5J”
CASE TEMPERATURE MANAGEMENT BLOWER SKID A168 VPR17-3

CC11

9019

CA79F

TO SHEET 2
ZONE A-7, “AD-5H” VPR17-5
2
S 20-TQ2-4
3
1

VPR17-6

CA79H
4 5 6 TO SHEET 2 I 65EP-19
3 ZONE A-7, “AD-5I” P

Ø 8.40
COMPRESSOR TURBINE ST1
[213 MM]
HEAT RATE CONTROL PANEL 1022

2
9 8 7

TURBINE COMPARTMENT 1634

NC NC NC

PT FROM SHEET 2 PT FROM SHEET 2 PT FROM SHEET 2

96-TS2P-1A ZONE C-4, “AD-9A” 96-TS2QP-1A ZONE C-8, “AE-13A” 96-TS3QP-1A ZONE B-8, “AE-9A”
NO NO NO

NC NC NC

PT FROM SHEET 2 PT FROM SHEET 2 PT FROM SHEET 2

96-TS2P-1B ZONE C-4, “AD-9B” 96-TS2QP-1B ZONE C-7, “AE-13B” 96-TS3QP-1B ZONE B-7, “AE-9B”
NO NO NO

NC NC NC

PT PT FROM SHEET 2 PT FROM SHEET 2

96-TS2P-1C 96-TS2QP-1C ZONE C-7, “AE-13C” 96-TS3QP-1C ZONE B-7, “AE-9C”
NO NO NO

PRESSURE TRANSDUCER ARR 557T

GE CLASS II (INTERNAL NON-CRITICAL)
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.

g GE Energy

DISTR
DRAWN
CANDELARIA, ARNOLD

TO
ISSUED
SEE PLM
SCALE SHEET
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DWG Number 232D7907 Rev - Released 9/21/2013 Page 1 of 2

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 107T7375 Rev - Released 6/19/2013 Page 1 of 3

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 107T7375 Rev - Released 6/19/2013 Page 2 of 3

GE Proprietary Information - Class II (Internal) US EAR - NLR

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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 232D7890 Rev - Released 10/7/2013 Page 1 of 5

       
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DWG Number 232D7890 Rev - Released 10/7/2013 Page 2 of 5

       

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DWG Number 104T2780 Rev - Released 5/23/2012

GE Proprietary Information - Class II (Internal)

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DWG Number 104T2780 Rev - Released 5/23/2012

GE Proprietary Information - Class II (Internal)

US EAR - NLR
Tab 14
 g
GEK 110425a
Revised, June 2008

GE Energy

9FA Natural Gas Only Cooling Water Systems

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.
GEK 110425a 9FA Natural Gas Only Cooling Water Systems

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.

 9FA Natural Gas Only Cooling Water Systems GEK 110425a

I. GENERAL

The cooling water system is designed to accommodate the heat dissipation requirements of the lubricating
oil system, turbine supports and flame detector mounts, generator gas coolers, and if required, the dual
tower hydrogen gas dryer and the LCI cooler. The components of the cooling water system are located on
the accessory module, the gas turbine base, the generator base, and where applicable, the LCI base and
gas dryer module. Components include heat exchangers (Plate and Frame/Shell and Tube), butterfly
valves, orifices, ball valves, needle valves and temperature regulating valves. Refer to the cooling water
schematic (MLI 0420) for further details.

All devices are set to give proper temperature, pressure, and flow. The settings for these devices can be
found in the device summary for the corresponding system.

Pipe and flow control means must be provided by others for interconnection of the subsystems.

Refer to GEI 41004 (Latest Revision) for cooling water recommendations for closed cooling systems and
GEK 28170 (Latest Revision) for open cooling systems.

II. FUNCTIONAL DESCRIPTION

A. Accessory Module
Lubricating Oil System
The lubricating oil cooling system components consist of two heat exchangers (LOHX1 & LOHX2),
a temperature regulating valve (VA32-1) and butterfly valves. Two heat exchangers are provided so
that one is in operation cooling the lubricating oil while the other one is being maintained. Only one
of the heat exchangers is to be in service during operation. The exchanger not in service must have
the coolant return isolation butterfly valve closed. Both supply and return isolation valves should not
be closed for an extended period of time on the inactive heat exchanger as this will then be an
enclosed volume. In an enclosed volume, any thermal fluid expansion could result in an external leak.
A high point vent and a low point drain are located on the pipeline.

To change from one heat exchanger to the other while the gas turbine is operating the following steps
are to be followed: 1) Open the lubricating oil fill valve and allow the heat exchanger to fill with oil
until flow is observed in the sight glass. 2) Open the closed coolant isolation valve on the exchanger
currently not in service. Coolant is now being circulated through both heat exchangers. 3) Operate the
oil transfer valve to direct the total oil flow to the heat exchanger that will now be in service. 4) Close
the coolant return isolation valve on the exchanger with no oil flow.

The temperature-regulating valve (VA32-1) is provided to control the lubricating oil header
temperature. The three-way valve bypasses coolant around the heat exchanger allowing the correct
coolant flow to maintain the oil within the temperature control range. An Electro-pneumatic
Temperature Controller (90LT-1) regulates the valve. If the oil temperature outside of the heat
exchanger exceeds the setpoint temperature, then the signal from 90LT-1 will open the control valve
further in the B-L position, allowing more coolant to flow through the heat exchanger and thus
reducing the oil temperature. If the oil temperature out of the heat exchanger is less than the setpoint,
then the signal out of 90LT-1 will open the VA32-1 valve further in the B-R position, reducing the
flow of coolant to the heat exchanger and thus reducing the oil temperature. On start up of the gas
turbine, the valve is usually closed to the heat exchanger and will open as the oil temperature reaches
the control temperature range. The Cooling Water Control Valve arrangement also includes a

© General Electric Company, 2008. GE Proprietary Information. All Rights Reserved. 3

GEK 110425a 9FA Natural Gas Only Cooling Water Systems

Pneumatic Pressure Regulator (VPR64-2). An override crank is also provided on the valve to allow
manual control.

NOTE

At high ambient temperatures, valve VA32-1 may open to full flow to the heat
exchanger. At this point the maximum coolant flow rate exists and the oil
temperature may rise above the temperature control range of the valve. This is
acceptable as the heat exchangers and the system are designed to keep the oil
temperature from exceeding the high oil temperature limit under any site ambient
condition.
B. Gas Turbine Base
The piping on the gas turbine base distributes coolant to the turbine supports if required, and flame
detector mounts. If applicable, the turbine supports are cooled so that thermal expansion is minimized
thereby keeping rotor shaft misalignment to a minimum.

The flame detector mounts are cooled to extend the life of the flame detectors. The coolant jackets on
the flame detector mounts provided a thermal break in heat transfer conduction between the
combustion can housing and the flame detector instrument.

No temperature regulation is necessary for the turbine supports or flame detector mounts. The flow
rates of cooling water designed into the piping system provide excess cooling, assuring negligible
impact on cooling water temperature.

GE recommends regular inspections of the flame detector cooling water system in order to maintain
proper performance.

These inspections should be conducted at every planned maintenance outage.

During these inspections, verify that the piping and tubing associated with the cooling water system
is properly supported and is not rubbing or abrading in any way. Check the entire cooling water
system for any damage, wear, loose fittings, interference, fretting, or anything else that may lead to
leaks or system malfunctions.

When inspecting flame scanner cooling coils, ensure that the clamp is not in contact with the cooling
tubes. Verify that the flame detector cooling coils are tight, with no relative motion between the
clamp and cooling coil.

Visually inspect for wear on the flame scanner cooling coils. If any wear is noted, the cooling coil
should be replaced immediately in order to avoid coolant leaks.

Finally, closely monitor the water level in expansion tanks. Any significant drops in the water level
may indicate a leak in the system.

Due to the potential for hardware damage and fire, the turbine base (flame detector) cooling water
system components should be given the same importance as the fuel system components. Regular
walk-downs of the system will allow maintenance issues to be identified and addressed early.
Damage and/or leaks which compromise system operation can be identified and repaired, which will
help protect the unit from potential performance reduction and hardware damage.

4 © General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.

 9FA Natural Gas Only Cooling Water Systems GEK 110425a

When installing, replacing, and/or maintaining flame detector cooling coils, ensure the edge of the
Sheet Metal Band is not in contact with the cooling tubes. This will ensure that no rubbing or fretting
of the cooling tubes by the band’s edge will occur during turbine operation. The torque value for the
cooling coil retainer must be 50 to 60 in. lbs (5.6 to 6.8 Nm).

C. Generator
The generator has four simplex hydrogen gas coolers mounted in the vertical position. Heat from the
closed circuit gas stream is transferred to the coolant through them. Isolation butterfly valves are
provided on the coolant inlet and outlet of each gas cooler to allow servicing of the coolers without
draining the entire cooling water system. Under normal operation, all four coolers must be valved
into the cooling water system. Refer to the generator operating instructions for cooler servicing
during unit operation.

D. LCI
If the LCI cooler requires water for cooling during unit start up, then the cooling water is also
supplied to the LCI cooler (Load Commutated Inverter). The recommended piping arrangement is for
the cooling water to the LCI cooler to be piped in parallel with the Generator coolers. If the LCIs are
cross-connected the piping arrangement shall be in such a way that the LCI that starts the unit gets
the water for cooling.

E. Dual Tower Gas Dryer (If Applicable)

The dual tower gas dryer contains a simple heat exchanger for use during the reactivation cycle of the
off-service tower. Refer to MLI G2SME for more detailed information on the dual tower gas dryer.
The heat exchanger lowers the temperature of the hydrogen being used to reactivate the desiccant in
the tower below its dew point, allowing moisture to be removed by the dryer unit’s moisture
separator. There are no isolation valves or instrumentation on the cooling water side of this
subsystem. The flow rate defined in the system schematic will provide the necessary cooling
regardless of cooling water temperature. Cooling water is not required for gas dryers employing a
single tower design.

© General Electric Company, 2008. GE Proprietary Information. All Rights Reserved. 5

GEK 110425a 9FA Natural Gas Only Cooling Water Systems

g GE Energy
General Electric Company
www.gepower.com

6 © General Electric Company, 2008. GE Proprietary Information. All Rights Reserved.

DWG Number 145E4550 Rev - Released 10/25/2012 Page 1 of 3

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DWG Number 145E4550 Rev - Released 10/25/2012 Page 3 of 3

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GE Proprietary Information - Class II (Internal) US EAR - NLR
Tab 15
 g
GEK 117015
January 2012

GE Energy

Ventilation and Heating System

For F Class Outdoor Gas Only Units

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 117015 Ventilation and Heating System

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Ventilation and Heating System GEK 117015

I. SCOPE

This document applies to an F class gas turbine utilizing a heating and ventilation system.

II. GENERAL

Heating and ventilation capabilities have been incorporated into the turbine compartment, accessory
compartment gas fuel region, accessory compartment lube and hydraulic oil region and load shaft
compartment. The purposes for ventilating the compartments are to dissipate heat generated inside the
compartment and to dilute any minor hazardous gas leakage. Each compartment is constructed with
thermally insulated side panels and roofs. The compartments are ventilated as shown in the schematic
diagram in the Reference Drawing section of this service manual.

Gravity operated inlet dampers and CO2 latched outlet dampers as shown on the reference schematic are
used in the system to automatically provide a tight enclosure when the fire protection system is activated.
The CO2 latched outlet dampers are normally held open by fire extinguishing agent pressure operated
latches that must be manually reset after damper release. When the agent is discharged, pressure on the
latch forces a piston against a spring, moving a locking lever that releases the latch allowing the damper
to close.

NOTE

It is imperative that all Turbine Enclosure access doors remain closed during
operation of the compartment ventilation system. Operation of the compartment
ventilation system with any access door open could compromise the effectiveness
of the ventilation system and adversely affect safety systems such as hazardous gas
detection and CO2 fire protection systems.

III. FUNCTIONAL DESCRIPTION

A. Accessory Compartment
The accessory compartment is divided into two regions: the gas fuel module region and the lube oil
and hydraulic oil region. A gas-tight barrier wall separates the two regions. In case of leak in the gas-
tight barrier wall, the negative pressure relative to atmosphere in the gas fuel module and the positive
pressure relative to atmosphere in the lube oil and hydraulic oil region assures that the direction of
airflow would be from the lube oil and hydraulic oil region to the gas fuel module. These pressures
are induced via the ventilation system.

The turbine compartment ventilation fan ventilates the gas fuel module region of the accessory
compartment. Ventilation air enters the gas fuel module through gravity-operated dampers in the
compartment side panels and exits the module through an opening to the turbine compartment.

Heater 23VS-3 is provided for humidity control in the gas fuel module region of the accessory
compartment when the ventilation system is not operating. The heater is energized based on the
readings of thermocouples AT-VS1/2.

Heater 23VS-1 is provided for freeze protection in the gas fuel module region of the accessory
compartment when the ventilation system is not operating. The heater has its own motor-driven
blower and is energized based on the readings of thermocouples AT-VS-1/2.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.
GEK 117015 Ventilation and Heating System

The ventilation system for the lube and hydraulic oil region consists of a fan driven by AC motor,
88BL-1 and 88BL-2. The fans are mounted on the roof of the lube and hydraulic oil region of the
accessory compartment.

Ventilation air enters the lube and hydraulic oil region through gravity-operated dampers on the
discharge side of the ventilation fan. Air exits the compartment through a discharge opening in the
compartment roof. A CO2-actuated damper is located at compartment ventilation discharge. This
damper is held in a normally-open position by a latch that is released when the fire protection system
is activated. The closure of this discharge damper, the automatic shutoff of the fans, and subsequent
closure of the gravity dampers, seal the lube and hydraulic oil region in the event the fire suppression
system is activated. In a lead-lag system, the gravity-operated backdraft damper located on each fan
prevents backflow through the standby fan.

During normal operation, the ventilation fan starts automatically when the lube oil pumps are running
and will continue to run when the unit fires. The fans are operated in a lead-lag configuration and if
the selected “lead” fan fails to operate as sensed by pressure differential switch 63AT-3 or 63AT-4,
the “standby” fan will start. When the unit is not firing, operation of the ventilation fan is controlled
by thermocouples AT-HL-1/2 located in the lube oil and hydraulic oil region of the accessory
compartment. As noted below, the same thermocouples are also used for activation of the humidity
control heater. The fan and heater are interlocked by thermocouples AT-HL-1/2 so that both the fan
and heater will not be energized simultaneously.

For humidity control during periods of shutdown and internal condensation during periods of
shutdown, the fan motor is equipped with heater 23BL-1 and 23BL-2.

Heater 23HL-3 is provided for humidity control in the lube oil and hydraulic oil region of the
accessory module when the unit is not operating. The heater is energized based on the readings of
thermocouples AT-HL-1/2.

Heater 23HL-1 is provided for freeze protection in the lube oil and hydraulic oil region of the
accessory compartment when the unit is not operating. The heater has its own motor-driven blower
and is energized based on the readings of thermocouples AT-HL-1/2.

B. Turbine Compartment
The ventilation system for the turbine compartment consists of a fan driven by AC motor, 88BT-1
and 88BT-2. The fans are mounted on the roof of the GT compartment.

Ventilation air enters the turbine compartment through gravity-operated dampers in the compartment
side panels and from the gas fuel module region of the accessory compartment as described above.
Air exits the compartment via a discharge opening and a CO2-actuated damper on the compartment
roof, a gravity actuated damper, and the ventilation fan.

The CO2-actuated damper is held in a normally-open position by a latch that is released when the fire
protection system is activated. The closure of this discharge damper, the automatic shutoff of the
fans, and subsequent closure of the gravity dampers, seal the turbine compartment in the event the
fire suppression system is activated. In a lead-lag system, the gravity-operated backdraft damper
located on each fan prevents backflow through the standby fan.

4 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Ventilation and Heating System GEK 117015

The turbine compartment vent fans provide heat dissipation from the enclosure as well as sufficient
dilution ventilation of any small hazardous gas leaks; large leaks will be detected by the hazardous
gas detectors and require appropriate action. During normal operation, the ventilation fan starts
automatically when the unit fires during startup. The system is operated in a lead-lag configuration
and if the selected “lead” fan fails to operate as sensed by pressure differential switches 63AT-
1A/1B/1C or 63AT-2A/2B/2C, the “standby” fan will start.

Following a shutdown, thermocouples AT-TC-1/2, located in the turbine compartment, control the
operation of the fan, causing it to start when the temperature exceeds the high temperature set point
and causing it to stop when the compartment temperature drops below the reset setting.
Thermocouples AT-TC-1/2 will cause an alarm to occur if the turbine compartment temperature
exceeds the high temperature alarm setting.

For humidity control during periods of shutdown, the turbine compartment fan motor is equipped
with heater 23BT-1 and 23BT-2.

Heater 23HT-3A and 23HT-3B are provided for humidity control in the turbine compartment when
the unit is not operating. The heaters are energized based on the readings of thermocouples AT-TC-
3/4. Thermocouples AT-TC-3/4 are located in the turbine compartment below the gas turbine.

Heaters 23HT-1A/ 1B are provided for freeze protection in the turbine compartment when the unit is
not operating. The heaters have their own motor-driven fans (88HT-1A and 88HT-1B) and are
energized based on the readings of the thermocouples AT-TC-3/4.

Thermocouples AT-TC-3/4 will also cause an alarm to occur if the turbine compartment temperature
drops below the low temperature alarm setting to indicate the failure of the turbine compartment
heaters.

C. Load Shaft Compartment

The ventilation system for the load shaft compartment consists of a fan driven by AC motor, 88VG-1
and 88VG-2. The fans are mounted on the roof of the load shaft compartment.

Ventilation air enters the load shaft compartment through gravity-operated dampers on the discharge
side of the ventilation fan. Air exits the compartment through a discharge opening in the
compartment roof. In case of a compartment fire, the fan motor stops and the gravity damper close. In
a lead-lag system, the gravity-operated backdraft damper located on each fan prevents backflow
through the standby fan.

The load compartment vent fans provide satisfactory heat dissipation from the enclosure as well as
sufficient dilution ventilation of any potential risk associated with close proximity to the hydrogen-
cooled generator. The load compartment ventilation system operates whenever the turbine is above
turning gear speed or when the hydrogen-cooled generator is pressurized. The fans are operated in a
lead-lag configuration and if the selected “lead” fan fails to operate as sensed by pressure differential
switches 63AG-1A/1B/1C or 63AG-2A/2B/2C, the “standby” fan will start.

For humidity control during periods of shutdown, the load shaft compartment fan motor is equipped
with heater 23VG-1 and 23VG-2.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
without prior permission of the copyright owner.
GEK 117015 Ventilation and Heating System

g GE Energy
General Electric Company
www.gepower.com

6 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
DWG Number 145E4539 Rev - Released 10/24/2012 Page 1 of 4

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GE Proprietary Information - Class II (Internal) US EAR - NLR
Tab 16
DWG Number 288D1036 Rev A Released 1/2/2013

GE Proprietary Information - Class II (Internal) US EAR - NLR

 GEK 111696

g
July 2007

GE Energy

Fire Protection System

These instructions do not purport to cover all details or variations in equipment nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further
information be desired or should particular problems arise which are not covered sufficiently for the purchaser's
purposes the matter should be referred to the GE Company.
© 2007 General Electric Company
GEK 111696 Fire Protection System

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2
 Fire Protection System GEK 111696

TABLE OF CONTENTS

I. GENERAL INFORMATION ..................................................................................................................4

II. FUNCTIONAL DESCRIPTION AND SYSTEM OPERATION ...........................................................4
III. INSTALLATION, MAINTENANCE AND TESTING...........................................................................7
IV. CO2 CONCENTRATION TEST INSTRUCTIONS ...............................................................................7

3
GEK 111696 Fire Protection System

I. GENERAL INFORMATION

The carbon dioxide fire protection system used for the gas turbine unit extinguishes fires by reducing the
oxygen content of the air in the compartment from an atmospheric normal of 21% to below the level
necessary to support combustion (normally 15%). To reduce the oxygen content, a quantity of carbon
dioxide (CO2) is discharged into the compartment in one minute to bring the CO2 concentration up to
34%. The system also provides an extended discharge to maintain an extinguishing concentration of 30%
for a prolonged period to minimize potential re-flash conditions.

The fire protection system design conforms to the requirements specified in NFPA Pamphlet 12 –
Standard on Carbon Dioxide Extinguishing Systems.

II. FUNCTIONAL DESCRIPTION AND SYSTEM OPERATION

To gain a better understanding of the fire protection system, a brief description of its operation and
distinctive features is provided in the following paragraphs. Refer to the fire protection system schematic
diagram (MLI 0426) located in the Reference Drawings section of the Service Manuals.

The fire protection system is comprised of a distribution system of piping for the delivery of CO2 from a
low pressure storage tank to the required gas turbine compartments in the event of a fire. This low
pressure storage tank is located on an off-base skid and maintains saturated liquid carbon dioxide at a
storage pressure of 300 psig (21.09 kg/cm2 or 2069 kPa) at 0°F (-18°C) by means of a refrigeration
compressor.

The compressor is sized to keep the CO2 tank properly refrigerated to maintain the CO2 at the proper
pressure. If the pressure cannot be maintained by the refrigeration compressor, the CO2 tank is equipped
with a bleeder valve to release a small amount of CO2. This will act to lower the tank pressure and auto-
refrigerate the CO2. A full port safety relief valve is fitted to the tank and will relieve pressure in the
unlikely event than the CO2 pressure continues to rise above the bleeder valve setpoint.

If customer requested, a dual refrigeration system can be supplied. Each refigeration system's compressor
(88FP-1A/ 88FP-1B) is sized to keep the CO2 tank at the proper pressure. The compressors will alternate
running cycles so that they each will accumulate similar operational hours over their lifetime. If a single
compressor cannot maintain the correct CO2 pressure, both compressors will operate together until the
pressure is maintained within the normal range.

The CO2 skid may be equipped with a Cold weather Package to keep the tank at normal operating
pressures during extended periods of extreme cold weather. This package maintains the CO2 tank
pressure between 295psi and 305psi. In addition, modifications to the instrumentation lines are provided
to insure that no condensation occurs, which prevents false readings from being displayed by the pressure
and liquid level gauges.

There are two main components in the cold weather package; heat trace tape and a pressure build
vaporizer (See 0426 schematic).

Heat trace tape: This is used on the instrumentation lines, which in turn prevents the vapor on the low
pressure side from condensing and turning into a liquid. It also prevents the high pressure liquid line from
losing pressure due to the cold weather.

4
Fire Protection System GEK 111696

Pressure Build Vaporizer: This device keeps the CO2 tank at a normal operating pressure by means of
vaporizing the cold liquid CO2 and recirculating the vaporized liquid back into the vapor space of the
tank. This unit starts and stops automatically, by sensing the CO2 tank pressure.

The CO2 tank supplier’s manual provides more information, and should be consulted for specific details.

The fire protection system control panel is usually mounted on the off-base skid (or in the turbine control
room if customer requested). The interconnecting field piping, which is usually supplied by the installer,
delivers the CO2 from the off-base skid to the gas turbine compartments, where it connects to the on-base
piping that distributes the CO2 into the compartments through nozzle orifices.

Two separate distribution systems are used: an initial discharge and an extended discharge. Within a few
seconds after actuation, sufficient CO2 flows from the initial discharge system into the gas turbine
compartments to rapidly build up an extinguishing concentration. A CO2 concentration is then maintained
by the gradual addition of more CO2 from the extended discharge system, compensating for compartment
leakage.

Carbon Dioxide flow rate is controlled by the size of the orifices in the discharge nozzles in each
compartment for both the initial and extended discharge systems. The orifices for the initial discharge
system are large, permitting the rapid discharge of CO2 to quickly obtain the extinguishing concentration
mentioned above. Orifices for the extended discharge system are smaller and permit a relatively slow
discharge rate to maintain an extinguishing concentration over a prolonged period of time (based on the
turbine frame size’s emergency roll down and cool down periods) to minimize the likelihood of a fire re-
igniting.

NOTE

The unit has multiple zones of fire protection, with each zone consisting of an
initial and an extended discharge. This allows each zone to act independently of the
other; a fire in one zone will not initiate a discharge of CO2 in the other zones.

Protection/detection is achieved by using separate “A” and “B” loops of heat-sensitive fire detectors.
Each fire detector is wired into the fire protection control panel in such a way that a single detector will
initiate the alarms. However, a signal from both an “A-loop” and a “B-loop detector is required to initiate
a CO2 discharge. Strobes and horns, as well as CO2 warning signs, are strategically positioned on the
outside and/or inside of the appropriate compartments to warn personnel of detected fires/CO2 discharges.

Should a fire occur in one of the protected compartments, the contacts of the heat sensitive fire detectors
will close and complete an electrical circuit that signals a pre-discharge sequence. The sequence includes
starting an electronic pre-discharge timer and charging a pneumatic timer (both are typically factory set
for 30 seconds, but are field adjustable to be set according to each site's specific egress time from each
compartment). The pneumatic sirens located in each zone annunciate during the time that the pneumatic
timer operates to provide an audible warning for anyone inside the compartment. The electronic
strobe/horns also continue to annunciate during this pre-discharge time.

After the pneumatic pre-discharge timer expires, CO2 pressure is directed to the correct pressure operated
valves on the tank's manifold. These valves then open and release CO2 into the inital and extended
interconnect piping for the particular compartment that is on fire.

The system may also be manually actuated by means of the manual toggle switches (43MRFP-x devices)
located on the outside of the Electrical Control Cabinet. If customer requested, there may also be manual

5
GEK 111696 Fire Protection System

release switches mounted on the enclosure external walls of the protected zones. These devices, which
will normally have 43MR nomenclature (refer to the system schematic), are equipped with a pin which
must be pulled before the pushbutton can be depressed to activate the system and discharge the CO2.
Actuation of the system, either automatically or manually, will trip the turbine to shut down, shut off the
ventilation system, trigger the electronic and pneumatic pre-charge timers (beginning the sequence
described above).

For the purpose of maintenance on the fire protection system or the gas turbine itself, the accidental
discharge of CO2 can be prevented by closing the main shut off valve/limit switch (33FP-1A) located on
top of the storage tank and by closing the ball valve/limit switch (33FP-2A) on the Pilot Vapor Line. If
customer requested, there may also be manual lockout valves/limit switches (which will normally have
33FP.X nomenclature) mounted in the interconnect piping near the protected zones for remote lockout of
CO2 discharge.

Initial and extended discharge timers, 2FP devices, are located in the electrical control cabinet and control
the length of time the solenoid valves are energized and thus the CO2 discharge time (these times are
factory set - refer to MLI 0426 for the specific times). After CO2 discharge, these timers must be reset by
depressing the timer reset buttons (62FP devices) located on the inside of the Electrical Control Cabinet
(this will also serve to shut off the alarms).

CAUTION

If the carbon dioxide system is to be effective, the compartment panels must be in place
and the compartment doors closed. There is sufficient CO2 in the system to compensate
for leakage through ventilation openings which are closed by gravity dampers or CO2
pressure operated dampers (which must be manually reset) and unavoidable cracks in
the package lagging. There is not enough to allow for uncontrolled escape of CO2
through open panels or doors.

WARNING

CARBON DIOXIDE, IN A CONCENTRATION SUFFICIENT TO EXTINGUISH

FIRE, CREATES AN ATMOSPHERE THAT WILL NOT SUPPORT LIFE. IT IS
EXTREMELY HAZARDOUS TO ENTER THE COMPARTMENTS AFTER
THE CO2 SYSTEM HAS BEEN DISCHARGED. ANYONE RENDERED
UNCONSCIOUS BY CO2 SHOULD BE RESCUED AS QUICKLY AS POSSIBLE
AND RESUSCITATED IMMEDIATELY. IT IS ESSENTIAL THAT
PERSONNEL BE ADEQUATELY TRAINED AS TO THE PROPER ACTION
TO TAKE IN CASE OF SUCH AN EMERGENCY.

To put the turbine in a safe condition upon detection of a fire, the following contacts provide signals to
the turbine motor control centers and/or turbine control panel to trip the unit prior to CO2 discharge.

Each protected zone is equipped with a contact (94F-xA) which is wired to the MCC to trip the
ventilation system prior to CO2 discharge. Each zone is also equipped with a contact (94F-xB) that is
wired to the Turbine Control Panel to trip the turbine prior to CO2 discharge. Finally, pressure switches
are located in the pilot line for each zone (63FP-xA devices). These switches sense when CO2 pressure is

6
Fire Protection System GEK 111696

introduced to the selector valve, and they send a signal to the MCC to trip the ventilation and turbine
operation upon CO2 release. This would be considered a backup to the other contacts listed above.

33FP-1A, 33FP-2A, and 63FP-1D comprise the supervisory circuit. If any of these switches sense the unit
is not ready, contact 30FP-3A is a customer contact which will change state to annunciate a “not-ready”
condition. This would indicate that the CO2 tank has been locked out. 30FP-1B is the same signal as
30FP-3A, but is wired to the turbine control panel.

Contact 30FP-2A is the trouble contact for customer use. This contact will change states if there is a
problem with any of the monitored devices, including: loss of AC power, short/open in a supervised
circuit (heat detectors, strobe/horns), ground fault, tank pressure, pilot solenoid circuit, tank pressure,
refrigeration system, etc. This contact annunciates a “fault condition” in the system, and action must be
taken to remedy the fault. 30FP-1A is the same signal as 30FP-2A, but is wired to the turbine control
panel.

III. INSTALLATION, MAINTENANCE AND TESTING

For installation, inspection, and maintenance of the fire protection system, refers to the vendor
instructions. For fire protection/detection system testing instructions, refer to MLI 0113.

IV. CO2 CONCENTRATION TEST INSTRUCTIONS

This test involves running a full CO2 concentration test consisting of both the initial and extended
discharges for each zone of protection. The initial discharge runs for 1 minute following the release of the
CO2; while the extended discharge runs simultaneously, but continues for the entire extended discharge
period. Due to varying site conditions, differing locations of the off-base supply of CO2 from the turbine,
and potential leaks in the lagging and piping, a CO2 concentration test is required to ensure the integrity
of the fire protection system design and compliance with NFPA 12 (a simple “Puff Test” is not
satisfactory to ensure the system functions and is designed properly). In order to perform the
concentration test, a qualified technician must be present to make sure the test is run properly. The
vendor, whose instruction manual follows this text, (or another qualified service provider) should be
contacted in order to locate and schedule a technician to come to the particular site and oversee the
concentration test.

The CO2 concentration test should be conducted per Fire Protections System Discharge Test Instructions
(MLI0113) and as follows:

1. Inspect the ventilation dampers in the accessory, turbine, load, and/or any additional compartments
that are being protected by CO2. They should all be latched in the OPEN position for the dampers
that have CO2 operated latches.

2. Check to make sure the predischarge timers that are located in the control panel are set for the
suggested 30 second time delay to allow personnel time to evacuate the compartment before CO2 is
released. The predischarge timers can be changed in the field if a different time delay is required.

3. Check to make sure all compartments protected by CO2 (except the bearing area where applicable)
have a minimum of two external CO2 warning signs applied, one on of each side of each
compartment for personnel warning.

4. Clear all personnel from the compartments and close all compartment doors. At this time, any
obvious cracks or leaks in the lagging should be sealed to ensure compartment integrity.

7
GEK 111696 Fire Protection System

5. Initiate the release of the CO2 by electrical means within the fire protection control panel: for LP
CO2 systems, toggle the control panel release switches to begin release of the CO2. Each zone should
be tested separately for both the initial and extended discharge. Upon initiating release of the CO2,
the fire alarm strobes and horns in the accessory compartment and in any other compartments should
be activated and be clearly heard. During the test, inspect the outside of each compartment to see if
quantities of CO2 are leaking out of cracks in the lagging, meaning compartment integrity has not yet
been achieved.

6. After the CO2 discharge has stopped, the applicable switches should be reset. A compartment
inspection should be carried out to verify that all ventilation dampers have functioned properly.
Once this operation has been performed, the dampers should be reset to the OPEN position.

WARNING

THIS DOCUMENT PROVIDES GUIDELINES TO CREATE A SITE SPECIFIC

PROCEDURE. BEFORE PERFORMING CO2 DISCHARGE TEST, A
SPECIFIC WRITTEN PROCEDURE SHALL BE CREATED. THIS
PROCEDURE NEEDS TO ADDRESS HAZARDS OF WORKING WITH HIGH
PRESSURE CO2 AND OUTLINE SAFE SITE WORK PRACTICES TO
PROTECT THE WORKERS (WORKING AT HEIGHTS, LOTO PROCEDURE
DURING ACCESS TO CO2 PROTECTED ENCLOSURE).

7. Upon successful completion of the CO2 concentration test, G.E. Design Engineering should be
consulted and the results of the concentration test should be sent to the appropriate design engineer
for design documentation purposes.

g GE Energy
General Electric Company
www.gepower.com

8
DWG Number 145E4547 Rev - Released 10/25/2012 Page 1 of 2

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GE Proprietary Information - Class II (Internal) US EAR - NLR
 GEK 110891a
Revised March 2006

GE Energy

FM-200 Fire Protection System

These instructions do not purport to cover all details or variations in equipment nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance. Should
further information be desired or should particular problems arise which are not covered sufficiently for
the purchaseŕs purposes the matter should be referred to the GE Company.
© 2006 General Electric Company
GEK 110891a FM-200 Fire Protection System

This document applies to a Stand Alone FM-200.

I. GENERAL INFORMATION

The FM-200 automatic fire suppression system used by the auxiliary unit compartments suppresses fire by
interrupting the combustion process and affecting the available oxygen content in the area of the discharge.
The system design requires that the FM-200 agent be discharged from its container within 10 seconds and be
thoroughly mixed throughout the room or area, reaching a minimum concentration of 7% but not exceeding
9% in normally occupied spaces. The system and its components should only be used for total flooding
applications, not local application protection. FM-200 systems are intended to suppress fires involving
equipment or specific hazards where an inert, electrically non-conductive agent is required, or when clean
up of other agents presents a problem. FM-200 is clean, efficient, environmentally acceptable, and leaves
no residue, thus minimizing any downtime after a fire.

The fire protection system design conforms to the requirements specified in NFPA 2001-Standard on Clean
Agent Fire Extinguishing Systems.

II. FUNCTIONAL DESCRIPTION AND SYSTEM OPERATION

FM-200 is stored as a liquid in steel containers and super-pressurized with nitrogen to 360 psig (2482 kPa)
to increase its discharge flow characteristics. When discharged, FM-200 will vaporize at the discharge
nozzles and effectively mix with the air throughout the protected area. These systems consist of three basic
components: Storage/distribution, control panels, and detection and alarm devices.

The FM-200 system should be designed to discharge between a minimum discharge time of 5 seconds and
a maximum discharge time of 10 seconds. The amount of toxic by-products formed during extinguishment
of flames is greatly reduced by discharging the agent in less than 10 seconds. Most materials contained in
areas protected by FM-200, such as aluminum, brass, rubber, plastics, steel, and electronic components,
are unaffected when exposed to FM-200.

***WARNING***

IN ACCORDANCE WITH NFPA STANDARD 2001 AND EPA

SIGNIFICANT NEW ALTERNATIVE PROGRAM (SNAP), PER-
SONNEL EXPOSURE TO FM-200 TOTAL FLOODING SYSTEM
CONCENTRATIONS SHALL BE LIMITED TO THE RESTRIC-
TIONS SHOWN IN THE FOLLOWING TABLE:

FM-200 Exposure Restrictions

Concentration Level Exposure Restriction
Below 9% No Restriction
9%, up to 10.5% Limit to 5 Minutes
Greater than 10.5% Avoid Any Exposure

Unnecessary exposure to FM-200 and decomposition products shall be avoided. The discharge of FM-200
into a hazard may cause a reduction in visibility for a brief period. Any direct contact with the agent can
cause frostbite.

2
FM-200 Fire Protection System GEK 110891a

III. INSTALLATION, MAINTENANCE, AND TESTING

For installation, inspection, and maintenance of the fire protection system, refer to the vendor instructions.

IV. OPERATION

For a detailed operational description of the FM-200 system, refer to the vendor instructions.

A brief synopsis is as follows:

Pre-discharge timers (which are usually factory set for a suggested 30 seconds to allow personnel to evac-
uate the compartments, but can be changed in the field if required) are located on the control panel and
control the time between the detection of the fire and the actuation of the solenoid valves. Once the CO2
release has begun, it will continue until the active cylinders are completely empty.

There are four smoke detectors associated with the system, (45Sxx devices). 2 smoke detectors are wired
into an “A” loop, and 2 smoke detectors are wired into a “B” loop. Should a single smoke detector sense
smoke in the compartment, the contacts of the smoke detectors will close and complete an electrical circuit
that causes the strobe and horns to annunciate, warning personnel of smoke detection. If both an “A”
and a “B” loop smoke detector sense smoke in the compartment, both detector’s contacts will close and
complete an electrical circuit that begins a pre-discharge alarm sequence resulting in discharge of FM-200
into the compartment. The FM-200 discharge occurs by a solenoid valve (45xx device) energizing and
allow FM-200 to flow from the cylinder to pressurize the pilot operated selector valve. FM-200 then flows
from the cylinder, through the discharge selector valve, into the piping distribution system, and into the
protected compartment.

The system may also be manually activated. Manual actuation can be performed pulling the manual dis-
charge lever, which allows FM-200 to flow from the cylinder to pressurize the pilot operated selector valve.
FM-200 then flows from the cylinder, through the discharge selector valve, into the piping distribution sys-
tem, and into the protected compartment.

***WARNING***

IT SHOULD BE NOTED THAT THERE WILL BE NO PRE-DIS-

CHARGE ALARM OR TIME DELAY BEFORE A MANUAL RE-
LEASE OF FM-200.

3
GEK 110891a FM-200 Fire Protection System

GE Energy
General Electric Company
www.gepower.com

4
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Equipment Service Manual

DIS-201
Fire Protection Skid
REV. ZONE SHEET DESCRIPTION DATE APPROVED

     

      
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DELETED FOR
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GENERAL ELECTRIC COMPANY

GE Power Generation
 VENDOR SUPPLIED
 GE NOT TO REVISE. GE REVISION LEVEL IS AS SHOWN ON THIS APPLIQUE.
THIS DOCUMENT FILED UNDER THE GE DRAWING NUMBER
 THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE
THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.

MLI: A068 1 OF 36
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Table of Contents

Section 1 Equipment Parts & Spares List

Section 2 System Technical Data
2.0 Understanding Carbon Dioxide
2.1 General
2.2 Control Actuation Operation
2.3 Scheduled Maintenance
2.4 Storage Unit
2.5 Tank Shut-Off Valve
2.6 Master/Selector Valve
2.7 Lock-Out Valve
2.8 Actuation Line Supervisory Pressure Switch
2.9 Pressure Regulator
2.10 Pressure Relief Valve
2.11 Discharge Nozzles

Section 3 Reference Drawings

Section 4 Component Descriptions

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Section 2
System Technical Data
2.0UNDERSTANDINGCARBONDIOXIDE
Carbondioxideisachemicalcompoundformedbycombiningoneatomofcarbonwithtwo
atomsofoxygen,andisexpressedbythemolecularformulaCO2.Carbondioxidecanexist
inanyoneorallthreestatesofmatter:solid,liquid,and/orvapor;dependingonconditions
oftemperatureandpressure.

Undernormalatmosphericconditions,carbondioxideexistsasacolorless,odorlessgas
whichisabout1.5timesheavierthanair.Carbondioxidewillnotburnorsupport
combustionandwillnotsustainlife.

Whenconfinedwithinasuitablepressurevessel,carbondioxidecanexistinanyofthree
statesofmatterdependingonconditionsoftemperatureandpressure.Thepointatwhich
allthreestatesmayexistisͲ69.9°F(Ͳ56.6°C)and60.4psig(4.2bar).Thisiscalledthetriple
point.Attemperaturesandpressureslowerthanthetriplepoint,carbondioxidemaybe
eitherasolidoravapor,againdependingonconditions.Dryice(solidcarbondioxide),ata
temperatureofͲ109.3°F(Ͳ78.5°C)atatmosphericpressure,sublimes(transformsdirectly
fromsolidintovaporwithouttheformationofaliquid).

Thecriticalpointofcarbondioxideis87.9°F(31.1°C)and1070.6psig(73.8bar).At
temperaturesandpressuresgreaterthan87.9°F(31.1°C)and1070.6psig(73.8bar),carbon
dioxideliquidcannotexist.Atpressuresandtemperaturesgreaterthanthecriticalpoint,
carbondioxideexistsonlyasasupercriticalfluid.

Attemperaturesandpressuresabovethetriplepointandbelowthecriticalpoint,carbon
dioxideliquidwithoverlyingvapormayexistinequilibriumwithinaclosedvessel.Within
thisrange,thereisadefiniterelationshipbetweentemperature,pressure,anddensity.
ByfollowingthevaporpressurecurveinFigure2.0,itbecomesobviousthatifyoudesireto
storeliquidcarbondioxideat70°F(21.1°C),thepressurevesselwouldhavetobebuiltto
withstandpressuresofaround840psig(57.9bar).Byfollowingtheliquiddensitycurve,
onefindsthattheliquidbecomeslessdenseasthetemperatureincreasesandat70°F
(21.1°C),theliquiddensityisaround47poundspercubicfoot(762kg/m3).


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Bycomparingthepressureandliquiddensityat70°F(21.1°C)[837.8psig(57.8bar)and
47.6poundspercubicfoot(762kg/m3)]withthepressureanddensityat0°F(Ͳ17.8°C)
[291.1psig(20.1bar)and63.65poundspercubicfoot(1020kg/m3)],itisobviousthat
relativelylargequantitiesofcarbondioxideliquidcanbestoredinrelativelysmall,thin
walledpressurevessels;hencelowͲpressurebulkstorageofCO2.

Theterm"lowͲpressure"isusedintheindustrytodescribethestorageofcarbondioxideat
lowtemperaturesbelowambient,usuallyaround0°F(Ͳ17.8°C).Itisarelativetermand
shouldnotbetakenliterally,asthepressuresinvolvedrangeuptoaround357psig(24.6
bar).





















Figure 2.0 – Carbon Dioxide Density and Vapor Pressure


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Table 2.0 – Physical Constants of Carbon Dioxide

Molecular Weight 44.01 lb/lb-mol 44.01 kg/kg-mol

Vapor Pressure at 70 °F (21.1 °C) at 32 °F (0 °C)
at 2 °F (-16.7 °C) at -20 °F (-28.9 °C) at -69.9 °F
(-56.6 °C) at -109.3 °F (-78.5 °C) 838 psig 491 psig 57.79 bar 33.86 bar
302 psig 200 psig 20.83 bar 13.79 bar
60.4 psig 0 psig 4.17 bar 0 kPa

Density of the gas at 70 °F (21.1 °C) at 32 °F (0

°C) 0.1144 lb/ft3 0.1234 1.833 kg/m3 1.977
lb/ft3 kg/m3

Specific gravity of the gas at 70 °F (21.1 °C) at 32

°F (0 °C)
1.522 1.524 1.522 1.524

Specific volume of the gas at 70 °F (21.1 °C) at

32 °F (0 °C) 8.741 ft3/lb 8.104 0.5457 m3/kg
ft3/lb 0.5059 m3/kg
Density of liquid, saturated at 70 °F (21.1 °C) at
32 °F (0 °C) at 2 °F (-16.7 °C) at -20 °F (-28.9 °C) 764 kg/m3 931
at -69.9 °F (-56.6 °C) 47.6 lb/ft3 58.0 lb/ft3
kg/m3 1016 kg/m3
63.3 lb/ft3 66.8 lb/ft3
1072 kg/m3 1179
73.5 lb/ft3
kg/m3

Sublimation temperature (1 atm) -109.3 °F -78.5 °C

Critical temperature 87.9 °F 31.1 °C
Critical pressure 1070.6 psig 73.81 bar, abs
Critical density 29.2 lb/ft3 468 kg/m3

Triple point -69.9 °F at 60.4 psig -56.6 °C at 4.16 bar

Latent heat of vaporization at 32 °F (0 °C) at 2 °F
(-16.7 °C) at -20 °F (-28.9 °C)
100.8 Btu/lb 119.0 234.5 kJ/kg 276.8
Btu/lb 129.6 Btu/lb kJ/kg 301.4 kJ/kg
Latent heat of fusion at -69.9 °F (-56.6 °C) 85.6 Btu/lb 199 kJ/kg
Density of liquid at 2 °F (-16.7 °C) 63.3 lb/ft3 1015.9 kg/m3

Latent heat of sublimation at -109.3 °F (-78.5 °C) 245.5 Btu/lb 571.0 kJ/kg

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2.0.1GENERALSAFETYCONSIDERATIONS
Gaseouscarbondioxideisanasphyxiate.Concentrationsof10%ormorecanproduce
unconsciousnessordeath.Lowerconcentrationsmaycauseheadache,sweating,rapid
breathing,increasedheartrate,shortnessofbreath,dizziness,mentaldepression,visual
disturbances,andshaking.Theseriousnessofthelattermanifestationsisdependenton
theconcentrationofcarbondioxideandthelengthoftimetheindividualisexposed.
Carbondioxideisanodorlessgasandshouldbetreatedasamaterialwithpoorwarning
properties.Itisdenserthanair,andhighconcentrationscanpersistinopenpits,tanks,or
lowdepressionsontheterrain.Beforeenteringsuchanarea,carbondioxidemonitoring
shouldbecarriedoutandtheareaclearedbyforcedventilation,oraselfͲcontained,
suppliedairrespiratorshouldbeworn.
Appropriatewarningsignsshouldbeaffixedoutsideofthoseareaswherehigh
concentrationsofcarbondioxidegascanaccumulate.Onesuchsignisshownbelow:

2.0.2RESCUE
Donotattempttoremovetheindividualwithoututilizingproperrescueequipmentoryou
mayalsobecomeacasualty.Iftheexposedpersonisunconscious,obtainassistanceand
putintoeffecttheestablishedemergencyprocedures.

2.0.3INHALATIONFIRSTAID
Inhalationofgaseouscarbondioxidecanadverselyaffectbodyfunction.Skin,eye,or
mouthcontactwithdryice(solidcarbondioxide)orcompressedcarbondioxidecancause
adverseeffects.

Ifapersonhasinhaledlargeamountsofcarbondioxideandisexhibitingadverseeffects,
movetheexposedindividualtofreshairatonce.Ifbreathinghasstopped,perform
artificialrespiration.Keeptheaffectedpersonwarmandatrest.Getprofessionalmedical
attentionimmediately.

2.0.4EXTERNALEXPOSUREFIRSTAID
Skinormouthcontactwithdryiceorwithvapororliquidcarbondioxidedischargedfroma
containermayresultinfrostbite,causingskinlesionsormoreseriousinjuryfromdeep
freezingofthetissues.

IfdryiceorcompressedCO2vaporcomesincontactwiththeskinormouth,stopthe
exposureimmediately.Iffrostbitehasoccurred,obtainprofessionalmedicalattention
immediately.Donotrubthearea.Donotapplyheatwarmerthan107°F(41.7°C).

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EyecontactwithdryiceorcompressedCO2shouldbeconsideredasacornealburn.
Frostbiteoftheeyestructuremayalsooccur.

IfdryiceorCO2vapororliquidcomesincontactwiththeeyes,stoptheexposureand
obtainprofessionalmedicalattentionimmediately

2.1.GENERAL

2.1.1Operationandserviceproceduresinthissectionareprovidedasaguidefor
identifyingandcorrectingsystemsfaults.Theuseoftheseproceduresbycompetent
personnelwillreducesystemdowntimeandminimizeunnecessarycosts.
Troubleshootingtablesareprovidedforidentifyingandisolatingsystem/component
faults.

2.1.2TheCO2systemshallbemaintainedinfulloperatingconditionatalltimes.Use,
impairmentandrestorationofthisprotectionshallbepromptlyreportedtothe
authorityhavingjurisdiction.

2.1.3Allcarbondioxidesystemsshallbethoroughlyinspectedandtestedforproper
operationbycompetentpersonnel.

2.2CONTROLACTUATIONOPERATION

2.2.1TheTomCO2FireSystemspneumaticactuationsystemisdesignedtominimize
thedependenceonvapor(pilot)pressure.Pilotactuationpressureisstillused,but
limitedtothoseconditionswhennormalandstandbyelectricactuationmethodsare
fullyoperational.Ifsystemelectricalpowerislost,thecontrolpanelisequippedwith
sufficientbatterybackͲuppowertomaintain24to48hourstandbypowerplus
enoughpowerforoneactuationsequence.Inaddition,asystememergency
mechanicaloverridefeatureisincorporatedasrequiredbyNFPA12.Theoverride
featureisamechanicaldevice,notrelyingonelectricalpower.Thisoverrideprovides
themostdependablemeansofemergencyoperation.

2.2.2 TherearethreebasicoperatingconditionsforallCO2fireprotectionsystems.
Theseconditionsincludestandby,actuationandsystemresetwhichwillfunctionally
restorethesystemtostandby.Eachoftheseconditionsisdescribedasfollows:

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2.2.2.1STANDBY
Whenthesystemisinstandby,thecontrolpanelawaitsasignalfromthedetection
networkoroneofthemanualstationsaboutthehazardarea.TheMaster,MasterͲ
SelectorandSelectorValves,whichlimitgasflow,arenormallyinaclosedposition.
Eachdischargevalveisfactoryfittedwitha24VDCsolenoidvalve,aninlinefilterand
connectorsforpneumaticͲelectricoperationviaasignalfromthecontrolpanel.
Figure2.1illustratesthatCO2vaporpressureisreducedfrom300psigto100psig
throughouttheactuationpressurenetwork.Asupervisorypressureswitchmonitors
thenetwork,signalingthecontrolpanelifactuationpressureisdecreaseddueto
leakorabreakinthepipe.ThedischargelineischargedwithCO2fromthediptube
uptotheMasterand/orMasterͲSelectorValve(s)onthestorageunitmanifold.In
standby,theallelectricͲpneumaticdischargevalvesremainclosedandtheir
correspondingsolenoidvalvesarenormallydeͲenergizedandinaclosedposition
also.

2.2.2.2ACTUATION

2.2.2.2.1Whenthesystemisactivatedbythedetectorsoramanualreleasestation,
theactuationisinitiated.Normalsystemactuationshouldalwaysdependprimarily
upontheelectricaldevicestoactuatethesystemtoassurepropersystemoperation
andthesafetyofthefacilitypersonnel.Thecontrolpanelenergizestheappropriate
dischargesolenoidvalve(s).Vaporpressureflowsthroughthesolenoidtothe
pneumaticoperatoratopthedischargevalve,asshowninfigure2.2.Thedischarge
valveopensallowingliquidCO2toflowthroughthepipetothedischargenozzles.
Thedischargewillcontinueuntilthesolenoidreleasedurationsettinghasexpired
andpowerisremovedfromthesolenoidcoil.

2.2.2.2.2Inraresituationswhenbothprimaryandstandbypowerarelostshould
theemergencyoverridefeatureofthesystembeusedtoactuatethesystem.The
emergencyoverrideoperationusesamanualvalveonthesolenoid.Whenthe
overridefeatureisoperated,theCO2dischargewillcontinueuntilthedischarge
valve(s)ismanuallyclosedorthestorageunitcontentsareexhausted.

2.2.2.3SYSTEMRESET
Followingthenormal(electricallyinitiated)dischargeperiod,thedischargevalve(s)
willcloseautomatically.Afterthesolenoid(release)circuithastimedout,poweris
removedfromthesolenoidcoil.Figure2.3showsthatwhenthesolenoidvalve
closes,flowisblockedfromthedischargeactuationport.Actuationpressure
trappedbetweenthesolenoidandthedischargevalveactuationportisreleasedout
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solenoidventport.Thisallowsthedischargevalvestoclose.LiquidCO2trapped
betweentheMasterValveandtheSelectorValvewillbereclaimedtothestorage
unitviathecheckvalvebypassaroundtheMasterValve.Vaporpressurefromthe
storageunitmaintainsactuationpressuretoreactivatethesystemifasecond
dischargeisrequired.Thesystemcontrolpanelandotherdeviceswillrequire
additionalresetprocedurestobringthesystemtonormalstandbycondition.





Figure 2.1 – Standby Condition

Fig. 2.2 – Actuation Condition

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Fig. 2.3 – System Reset



2.3SCHEDULEDMAINTENANCE
Table2.1isprovidedasaguidetoassistindesigningaspecificmaintenance
program.Theseitemsshouldbeincorporatedintothecompletemaintenance
program.Maintenanceshallonlyperformedbycompetentpersonnel.

Table 2.1 – Recommended Test and Maintenance Procedure

Check Weekly Monthly Annually What to Check
CompleteSystem   X Allcomponentsofthesystemshould
bethoroughlyinspectedandtested
forproperoperationtoinsurethe
systemisinfulloperatingcondition.
LiquidLevel X   Alsoinspectaftereachoperation.If
containershowsmorethan10%loss,
itshallberefilled.
TankPressure X   Visuallyinspectpressuregaugeto
seethatpressureintankiswithin
normalrangeof295Ͳ305psig.

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Check Weekly Monthly Annually What to Check

PowertoUnitRefrig. X   Checktoseethatalldisconnect
switchesareclosedandthatmain
powerisenergized.
VaporandFillLines X   Checkthatliquidfilllineandvapor
equalizingvalvesareclosed.
CarbonDioxideLeakage  X  Checkforcarbondioxideleakagearoundatall
valvepackingglands,fittingsandthroughseats
ofreliefvalves.
Exteriorconditionof X Checkfordeteriorationorseparationof
storagetank covering.Replacedeterioratedcoveringor
insulationasrequired.
Refrigeration X 1.Checkallrefrigerantlineconnectionsfor
system leakage.
2.Checkcondensingunitcoilsandmotorfor
heavydustanddirtdeposits.Cleanas
necessary.
Safetyreliefvalves  X  Checkforvisiblesignsofleakage,tamperingor
(tank&system) blockage.
High&lowtank  X  Checkoperationofpressureswitch
pressuresupervision
TankshutͲoffvalve X  X 1.Valveposition.
2.Operatevalvetofullyclosedposition,then
reͲopenvalve.Checkforleakage.
Master/Selector X   Checktamperindicatoronemergencymanual
Valves actuator.Verifyvalvestemisinneutral
positionand
sealed.
Master/Selector X   WithtankshutͲoffvalveclosedenergizethe
Valves solenoidandobserveoperationofvalve.Reset
systemandoperatemechanicaloperatoron
valve.Returnoperatortoneutralposition.
Checkforanyleaks.
Solenoidvalve X   Checktomakesurefilterisnotpluggedor
sinteredbronzefilter clogged.
Actuationline  X  WithtankshutͲoffvalveclosedclosethe
supervisorypressure controlvalveontheactuationlineandbleed
switch pressureoutofline.
Actuationline X   Checktomakesure100PSIGisbeing
maintainedinactuationline.

Note:Theaboverecommendedinspectionscheduleisconsideredasaminimumrequirement.Authorities
havingjurisdictionorinsurancecompaniesmayrequireamorestringentinspectionschedule.

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DWG Number GEK117012 Rev B Released 7/28/2014 Page 1 of 16

)
GEK117012b
Revised, July 2014

GE Power & Water

Aspirated Hazardous Gas Protection System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

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GEK117012b Aspirated Hazardous Gas Protection System

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to ensure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY.

2 © 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

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Aspirated Hazardous Gas Protection System GEK117012b

TABLE OF CONTENTS

I. GENERAL ...................................................................................................................................... 5

A. Definition of Terms ................................................................................................................... 5
B. General Purpose and Operation ................................................................................................. 5
II. SYSTEM OPERATION ................................................................................................................ 6
A. Turbine Enclosure ..................................................................................................................... 6
B. Gas Valve Module ..................................................................................................................... 7
C. Generator Enclosures ................................................................................................................ 7
III. SYSTEM FUNCTION ................................................................................................................... 7
A. Aspirated Sensors ...................................................................................................................... 7
B. Power Supply ............................................................................................................................ 9
C. IR Sensor ................................................................................................................................... 9
D. Catalytic Bead Sensors ............................................................................................................ 10
E. Lower Explosive Limits (LEL) ............................................................................................... 10
IV. RECOMMENDATIONS, ALARMS AND MAINTENANCE ................................................ 11
A. Sheath Membrane Inspection .................................................................................................. 12
B. Coalescing Filter Inspection .................................................................................................... 12
C. Bump Checks .......................................................................................................................... 12
D. Sample Draw Tubing Leak Check .......................................................................................... 12
V. TROUBLESHOOTING .............................................................................................................. 13
A. Low Flow Indication ............................................................................................................... 14
B. Instrument air pressure ............................................................................................................ 14
C. Coalescing filter ...................................................................................................................... 14
D. Sheath Membrane Filter .......................................................................................................... 14
E. Flow switch ............................................................................................................................. 14
F. Exhaust line ............................................................................................................................. 14
G. Gas sample flexible tubing ...................................................................................................... 14
H. 3-Way Valve............................................................................................................................ 14
I. Orifices .................................................................................................................................... 14
VI. RECOMMENDED SPARES ...................................................................................................... 14

© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.

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GEK117012b Aspirated Hazardous Gas Protection System

LIST OF FIGURES

Figure 1. Schematic Diagram of 2 Sensor Aspirated LEL Panel .......................................................................... 9

LIST OF TABLES

Table 1. Terms and Definitions ............................................................................................................................. 5

Table 2. Recommended Maintenance ................................................................................................................. 12

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Aspirated Hazardous Gas Protection System GEK117012b

I. GENERAL

A. Definition of Terms

TERM DEFINITION
Catalytic Bead LEL Sensor A catalytic bead sensor accelerates the combustion reaction to
cause a temperature change within the sensor, which is measured
and correlated to the LEL concentration. Detects H2. See Catalytic
Bead Sensors for more detail.
Fault A fault condition is a general indication that the system is not
operating properly. A fault signal is equivalent to a High-High LEL
signal in terms of control actions.
LEL Lower explosive limit. The lowest concentration of a combustible
gas that will theoretically explode. In practice, concentrations are
displayed as a percent of the LEL. See LEL section for more details
High LEL High LEL, also called the alarm threshold, is a predefined
combustible gas concentration above which a sensor will signal an
alarm on the HMI, but will not affect turbine operation.
High-High LEL High-High LEL, also called the trip threshold, is a predefined
combustible gas concentration above which a sensor will output an
alarm as well as a vote to trip. Two votes to trip are required to trip
the turbine.
IR LEL Sensor An Infrared (IR) LEL sensor measures the absorption of an IR
beam to measure combustible gas concentration. Does not measure
H2. See IR Sensors for more detail.
Startup Permissive A startup permissive sensor will prevent the turbine firing if it reads
a high, high-high, or fault condition.

Table 1. Terms and Definitions

B. General Purpose and Operation

The hazardous gas protection system provides monitoring of combustible gases inside equipment
areas for protection of personnel and equipment. This GEK addresses aspirated IR LEL sensors for
detection of methane, propane, ASL, and naptha, and aspirated catalytic bead LEL sensors used to
detect hydrogen and/or methane and propane.

IR sensors are used where hydrocarbon fuels are present whereas catalytic bead sensors are used for
hydrogen detection (See sections below for details on each sensor type).

A description of the system overall purpose and operation is provided below. For further details, refer
to the gas protection schematic (MLI 0474), also called the hazardous gas detection schematic,
located in the Reference Drawings section of the Service Manuals.

1. Sampling / Monitoring - General

Combustible gas sampling and monitoring is performed in areas where combustible gases are
likely to be found in the event of a gas leak. These areas include:

a. Gas turbine compartment, with sampling typically done inside the ventilation exhaust duct

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GEK117012b Aspirated Hazardous Gas Protection System

b. Fuel gas valve module, with sampling typically inside ventilation exhaust duct or air outlet

c. Liquid Fuel Module when burning Naptha or ASL, with sampling typically inside ventilation
exhaust duct.
2. Additional Sampling / Monitoring
In some configurations, combustible gas sampling and monitoring will also be done in:

a. Generator compartment, often on the collector (brush) end (H2 cooled generator only)

b. Generator terminal enclosure (H2 cooled generator only)

3. Purpose
The purpose of this system is to provide continuous monitoring of enclosures with the potential
for gas leaks. The system will inhibit turbine startup or the energization of generator collector
brushes if gas LEL levels are at or above alarm levels in the collector, terminal, gas valve
module, or gas turbine enclosures.

The system will provide an alarm indication on the HMI if the gas LEL reaches a predefined
high level based on the system configuration. In addition, the system will provide an automatic
trip of the Gas Turbine and Generator if High-High levels are detected in two sensors in an
active area in accordance with the design principle.

II. SYSTEM OPERATION

A. Turbine Enclosure

For most applications, the turbine enclosure utilizes two aspirated IR LEL sensors per ventilation
duct to monitor hazardous gas levels. Select applications also utilize a single, local sensor within the
turbine enclosure. For the exact number of sensors see the schematic for hazardous gas detectors
(MLI 0474).

1. If more than one ventilation duct exists, only the active duct is monitored for gas levels during
normal operation.

2. All the sensors within the turbine compartment are a startup permissive in that if any alarm or
fault signal is generated the turbine will not fire.

3. High LEL alarms will be generated by any sensor detecting an LEL at or above the alarm
threshold. See Recommendations, Alarms & Maintenance on operation with High alarm levels.

4. If High-High LEL levels are confirmed by at least two sensors, an automatic trip will occur.

5. For enclosures with dual ventilation blower designs, ventilation failure or two sensors in fault
will result in an automatic activation of the lag fan in the inactive ventilation duct and LEL
monitoring will shift to the other duct. At this time the original duct will become inactive.

6. The LEL sensors in the turbine enclosure are of the aspirated type to eliminate outage time for
calibration and facilitate ease of maintenance. See Aspirated Sensors below for further
information regarding operation, calibration, bump checks, and sample delivery.

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Aspirated Hazardous Gas Protection System GEK117012b

B. Gas Valve Module

1. The hazardous gas protection system in the gas valve module is comprised of aspirated IR
sensors; for exact number of sensors, refer to the schematic for hazardous gas detectors (MLI
0474).

2. Typically, each extract duct vent has one duct and multiple sensors. There also may be a local
sensor which responds to samples from the module.

3. The sensors in the duct are startup permissive as part of the protective system. LEL sensors will
signal an alarm if the high threshold is reached. (Refer to Recommendations, Alarms &
Maintenance for information on operation with high alarms.)

4. An automatic trip will occur if two of the extract duct LEL sensors read high-high. All gas valve
module sensors are of the aspirated type. See the section on Aspirated Sensors below for further
information regarding operation, calibration, bump checks, and sample delivery.

C. Generator Enclosures

If the generator scope is applicable, an aspirated, catalytic bead sensor shall be used for hydrogen-
cooled generator compartments.

Typically for hydrogen-cooled units, the generator system includes a total of five aspirated, catalytic
bead LEL sensors in two zones: the terminal enclosure and the collector enclosure.

1. Terminal Enclosure
The terminal enclosure contains two LEL sensors, both of which are used for startup permissive
and alarm functions only. The sensors will signal an alarm if the High or High-High LEL level is
reached but these sensors do not force a trip during fired operation.

2. Collector Enclosure
The collector enclosure contains three LEL sensors. These LEL sensors are used as startup
permissives and will send an alarm signal in the event of a High alarm level.

a. If two of the three sensors read a High-High LEL concentration during operation of the
turbine, then the turbine will automatically trip.

b. If two of the LEL sensors read a fault condition the turbine will go into a fired shutdown.

c. If one of the LEL sensors is in a fault condition and the remaining LEL sensor reads High,
the unit will automatically trip.

III. SYSTEM FUNCTION

A. Aspirated Sensors

1. An aspirated sensor refers to a system which extracts a gas sample from the location of interest
and transports the gas sample to LEL sensor(s) located in an accessible area.

a. Instrument air is used with an aspirator to create a low pressure zone, which inducts the flow
through the sample draw system.
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GEK117012b Aspirated Hazardous Gas Protection System

b. A non-orientation sensitive sample probe, with a sheath membrane filter to exclude debris, is
used to extract representative enclosure atmosphere gas samples through flexible stainless
steel hose or hard tubing to the LEL sensor panels.

2. An LEL sensor panel includes a coalescing filter for each LEL sensor, each with continuous
blow-down to remove debris or liquid.

a. A three-way valve, activated by a push button, is used to select between sample gas and
calibration gas flowing to the LEL sensor.

b. In the normally open condition the valve will allow the sample gas to flow; when closed, the
valve allows the calibration gas to flow.

c. A flow switch monitors and signals low flow conditions, and the LEL sensor (IR or catalytic
bead) measures the %LEL concentration.

d. A visual flow indicator provides a local indication of the sample draw flow-rate in each
sample draw line. The sample stream is exhausted back into the enclosure from which it was
taken, or to an adjacent, existing area designated as hazardous.

3. Figure 1 shows a schematic diagram of an aspirated, two-sensor LEL sampling and monitoring
system.

a. Refer to Recommendations, Alarms & Maintenance for maintenance information on each

component.

b. Relocating the LEL sensors to an accessible area allows the sensors to be calibrated or bump
checked without taking the turbine offline.

4. During calibration, the LEL sensor outputs a unique calibration signal. Note that when a sensor is
in calibration, the Turbine Controller will interpret the condition as equivalent to a High-High
LEL measurement.

5. It is critical to avoid calibrating two sensors simultaneously, or calibrating an LEL sensor if the
other sensors are not healthy (fault) in the same sampling region as doing so will result in a
forced shutdown of the gas turbine and generator.

6. For calibration procedure, refer to the Vendor supplied procedure located in the GE O&M
Service Manual in the section on GT Auxiliary Systems. It is recommended that the calibration
and bump check be performed while gas turbine is shutdown to prevent tripping a turbine that is
running.

7. The remote location of the LEL sensors introduces a time delay to the sensing of an LEL
concentration change in the monitored enclosure. To mitigate the risk of delay, flow switches are
used to ensure that if the sample delivery time decreases below predefined limits, the flow switch
will indicate a fault condition.

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Aspirated Hazardous Gas Protection System GEK117012b

Figure 1. Schematic Diagram of 2 Sensor Aspirated LEL Panel

B. Power Supply

The hazardous gas protection system is typically powered by redundant power supplies located in the
PEECC. Power is supplied by multiple 100% capacity power supplies to ensure uninterrupted power.

1. To ensure reliability, each LEL sensor/flow switch group will have its own dedicated power cable
and circuit protection.

2. The power supply is configured with fusible disconnects for maintenance and protection.

3. During calibration or maintenance it is important not to disconnect two LEL sensors at the same
time which are located in the same monitoring zone.

4. A sensor without power is considered a vote for high-high LEL and two sensors without power,
or one LEL sensor without power and one in a fault, measuring high-high, or calibration
condition in the same monitoring group, will cause the turbine and generator to trip.

C. IR Sensor

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GEK117012b Aspirated Hazardous Gas Protection System

Infrared (IR) sensors operate on the principle that each molecule absorbs a spectrum of
electromagnetic radiation. Some combustible gases of interest such as methane, propane, and most
other hydrocarbons absorb radiation in the infrared range; hydrogen does not.

The main components of an IR sensor are an IR source and two detectors.

1. The IR source generates a spectrum of frequencies in the IR band and emits the beam through an
internal window. This beam is sent through the gas sample, containing some IR absorbing
species, reflected off a mirror, split into two beams, and received by two detectors.

2. The detectors, called the analytical and reference detectors, are able to convert the IR radiation to
an electric voltage. The analytical detector is sensitive to the specific frequency that hydrocarbons
absorb and the reference detector is not.

As more IR absorbing gas is present in the sample, the intensity of the radiation incident on the
analytical detector decreases while the reference detector reading does not change. The voltage
difference between the reference and analytical detectors is proportional to the concentration of gas
present. The concentration is displayed as %LEL. Due to the fact that hydrogen does not absorb IR
radiation, this sensor will not detect its presence.

D. Catalytic Bead Sensors

Catalytic bead sensors operate by catalyzing a combustion reaction, causing a change in temperature.
This temperature change alters the electrical resistance of the catalyst material, as measured by a
circuit. A catalyst enables a chemical reaction to occur with less activation energy than normally
required.

1. A catalytic bead detector contains an active bead and a reference bead; the reference bead is
isolated from the gas. As a combustible gas molecule comes into contact with the active bead's
surface, the molecule binds to the surface and is able to combust at a temperature far below the
typical combustion temperature.

2. The reference bead is isolated from the gas sample and no combustion takes place there. This
catalyzed combustion raises the temperature of the active bead and, as a result, changes the
electrical resistance of the material.

3. The difference between the electrical resistance of the active and reference beads is proportional
to the gas concentration present in the sample.

E. Lower Explosive Limits (LEL)

Combustible gas sensors provide a reading of the gas concentration as a percentage of the lower
explosive limit (%LEL).

1. The LEL is the lowest concentration of a substance that will produce a fire or flash when exposed
to an ignition source, such as a flame or spark. The concentration varies depending on the type of
gas. The LEL is expressed in percent of vapor or gas in the air by unit volume. Below the LEL,
the gas mixture is too lean to burn. For example, the LEL of methane is 5.0% of the total volume.

2. The % LEL reading on a gas sensor is a percentage of the LEL value. At 100% LEL, the
minimum percentage of gas to support ignition is present, therefore the hazardous gas protection
system seeks to maintain any concentration of combustible gas below this level.
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Aspirated Hazardous Gas Protection System GEK117012b

3. In practice, combustion of a gas can occur at far below the LEL due to localized concentration
pockets.

4. To mitigate this risk, high alarms are set at 10% LEL or lower and high-high alarms are set at
25% LEL or lower, see Device Summary for settings (MLI 0414). A common sensing range for
combustible gas sensors is from 0 to 100 % LEL.

5. It should be noted, that gas detector readings may indicate higher or lower concentrations in other
parts of the compartment. For example, a 20% LEL reading in the extract duct may indicate that a
50% LEL cloud is present in an area inside the compartment.

IV. RECOMMENDATIONS, ALARMS AND MAINTENANCE

NOTE

In the event that an alarm is indicated it is not recommended to continue running

the unit.
While no action is taken by the control system outside of an alarm, this is an
indication that something has changed in the unit and should be investigated.
It is recommended to shut down the unit at the nearest opportunity to investigate
and repair the issue before returning the unit to service.
It is recommended that all maintenance be conducted while turbine is not running
or shut down to prevent tripping a turbine which is running.

Regular maintenance is essential to ensure proper functionality and long life for the system. Table 1
shows the recommended maintenance for each component of the system.

RECOMMENDED
DEVICE MAINTENANCE INTERVAL
Flow Switch Check Set Point 1 year
Sheath Filter Membrane Inspect 1 year*
Replace As Needed
Coalescing Filter Inspect 3 months
Replace As Needed
IR LEL Sensor Zero Check 6 months
Bump Check 6 months / first available opportunity
Calibrate Only if Bump Check Fails
Replace Upon Failure
Catalytic Bead Sensor Calibrate 90 days
Replace Upon Failure
Sample Draw Tubing Integrity Leak Check Upon Initial Installation
Leak Check 12 Months
Note:

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GEK117012b Aspirated Hazardous Gas Protection System

*Generator Terminal enclosures are subject to carbon dust being present in the atmosphere due to normal
collector brush wear. This has the propensity to be a variable in atmospheric contaminants on a site specific
basis. Sites with high levels of carbon dust may be required to decrease maintenance intervals on the sheath
filter membranes and replace the membrane more frequently
Refer to Section 5IV.D for more information.

Table 2. Recommended Maintenance

A. Sheath Membrane Inspection

To inspect the sheath filter membrane of the sample probe, remove the probe from the sample
location according to the vendor provided instruction manual and visually inspect the membrane.

1. The membrane should be white in color with no discoloration, perforations or obvious signs of
contamination.

2. Sheath membranes that are discolored coupled with decreased sample draw flow rates as verified
by the local flow gauge or a flow switch signal require replacement.

B. Coalescing Filter Inspection

To inspect the coalescing filter element, a visual inspection is required at the specific aspirated LEL
panel of interest.

1. The coalescing filter is housed in a clear colored housing for ease of visual inspection.

2. The filter media shall be white in color, with no obvious signs of discoloration or particulate
build up.

C. Bump Checks

Bump checks involve the application of a known calibration gas to the given LEL sensor (IR) and
recording the instrument response to the stimulus.

1. The value should be recorded at each maintenance interval and is considered the “as found”
condition. Catalytic bead LEL sensors, by design, tend to drift or degrade through the life of the
sensor.

2. If the as found condition supports that the sensor response is more than +/-3% different from the
stimulus, it is recommended to decrease maintenance intervals such that instrument response
remains within +/- 3 % of the stimulus.

a. For example, if the stimulus (calibration gas) is 50% LEL, and the as found condition (sensor
response) is 47.5% LEL, this is within acceptable tolerance.

b. Conversely if the same stimulus is used as the above example and the sensor response is 46%
LEL, it is recommended to reduce calibration intervals going forward such that the sensor
response is within +/- 3% of the stimulus.

D. Sample Draw Tubing Leak Check

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Aspirated Hazardous Gas Protection System GEK117012b

As enclosure gas samples are being drawn through a tubing system to remotely mounted LEL
sensors, the integrity of the sample draw tubing is critical. Leaks in the sample draw tubing system
have the potential to dilute the gas sample resulting in LEL measurements that are less than actually
present in the given enclosure.

1. In order to ensure that the sample draw tubing system is free from leaks, functional checks are
recommended at initial installation of the system and at the interval specified in Table 1.

a. Quick Connect Fittings

To check the integrity of sample draw tubing systems employing quick-disconnect fittings, it
is recommended to disconnect one sample draw line per enclosure, at the location closest to
the enclosure. As the Quick Connect fittings used are a double shut-off design, flow will
automatically be isolated to the LEL sensor and flow switch in that sample line.

b. Standard Tube Unions

To check the integrity of sample draw tubing systems not using Quick Disconnect fittings
(standard tube unions are used), it is recommended to disconnect one sample draw line per
enclosure at the location closest to the enclosure. Once the sample line is disconnected, the
user should temporarily plug the sample draw line for test purposes.

2. When these integrity check are performed, the flow switch in the given sample line will
annunciate an alarm as the sample draw flow rate will drop below pre-defined limits.

a. The associated visual flow gauge for the given sample line should be inspected to ensure that
flow is not present in the sample draw line being tested.

b. Presence of flow as observed by the visual flow meter, or a failure of the given flow switch to
result in annunciation of an alarm indicate a leak is present.

NOTE

Leaks shall be located and repaired.

3. In the same enclosure only one sample draw line may be tested for integrity at a time. Do not
test more than one sample draw line per enclosure concurrently; testing more than one sample
line for the given (same) enclosure will result in two (or more) flow switch faults.

4. As a flow switch fault is considered to be a vote for High-High LEL, the turbine generator will
trip if this condition (two or more faults) is realized in the same monitoring zone.

5. It is recommended to monitor local sample draw flow rates to observe any trends in decreasing
flows which may provide an early indication of carbon dust plugging the sheath membrane. If a
decreasing sample draw flow rate is observed, schedule and plan for earlier maintenance on the
sheath filter. If significant plugging of a sheath filter does occur, it will present itself in the form
of decreased sample draw flow rates and may result in a system fault on a specific sample draw
line as indicated by the flow switch.

V. TROUBLESHOOTING

In the event of a fault indication check the following issues:

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GEK117012b Aspirated Hazardous Gas Protection System

A. Low Flow Indication

If the sensor indicates low flow there is likely an obstruction in the flow circuit. First, check the
visual flow indicator to ensure there is lack of flow. If there is indeed low flow, the following steps
will check the components likely at fault.

B. Instrument air pressure

Ensure that there is ample instrument air pressure per GEK 110727. Also check the gauge on the
panel to ensure regulator pressure output.

C. Coalescing filter

Visually inspect the filter housing. It should be white and free of dirt. If discoloration is apparent
replace the filter.

D. Sheath Membrane Filter

Remove the sample probes one at a time and inspect the sheath membrane filter. The material should
be free of any dirt or obvious contamination. If discoloration is apparent, replace the sheath
membrane filter.

E. Flow switch

It is possible for the flow switch to drift from its set point. If this is the case the flow switch must be
removed and sent to the manufacturer for testing and/or recalibration. It is recommended to have a
backup flow switch on hand for this situation.

F. Exhaust line

Ensure the exhaust line is not obstructed.

G. Gas sample flexible tubing

Ensure the tubing is free from kinks or sharp bends, obstructions and is properly connected on both
ends

H. 3-Way Valve

Ensure that the 3-way valve is not out of position and the failsafe mechanism is operating properly.

I. Orifices

The flow circuit is balanced by two small orifices that could become obstructed if a particle gets past
the filters. Remove the orifices from the circuit, ensure they are clear, and reinstall.

VI. RECOMMENDED SPARES

The following are recommended to have on hand:

1. IR LEL Sensors (if used)

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Aspirated Hazardous Gas Protection System GEK117012b

2. Catalytic Bead Sensors (if used)

3. Coalescing Filters

4. Sheath Membrane Filters

5. Flow Switches

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GEK117012b Aspirated Hazardous Gas Protection System

)GE Power & Water

General Electric Company
www.gepower.com

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WG Number 103T1401 Rev - Released 4/10/2012

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Tab 18
DWG Number GEK111898 Rev D Released 1/31/2014 Page 1 of 12

GEK 111898d

g
Revised, November 2012

GE Energy

F Class Gas Turbine Compressor Water Wash System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 2 of 12

GEK 111898d F Class Gas Turbine Compressor Water Wash System

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 3 of 12

F Class Gas Turbine Compressor Water Wash System GEK 111898d

TABLE OF CONTENTS

I. GENERAL ..............................................................................................................................................4
A. On–Base Supplied Equipment............................................................................................................4
B. Off–Base Equipment..........................................................................................................................4
C. Functional Description.......................................................................................................................4
D. System Operation ..............................................................................................................................5
II. FALSE START DRAIN SYSTEM (APPLIES TO DUAL FUEL UNITS ONLY)..............................10

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 4 of 12

GEK 111898d F Class Gas Turbine Compressor Water Wash System

I. GENERAL

Gas turbines can experience a loss of performance during operation as result of deposits of contaminants
on internal components. This loss is indicated by a decrease in power output and an increase in heat rate.
The deposit of atmospheric contaminants on compressor parts occurs with the ingestion of air.

The ingested air may contain dirt, dust, insects, and hydrocarbon fumes. A large portion of these can be
removed before they get to the compressor by inlet air filtration. The dry contaminants that pass through
the filters as well as wet contaminants, such as hydrocarbon fumes, have to be removed from the
compressor by washing with a water–detergent solution followed by a water rinse.

A. On–Base Supplied Equipment

The on–base turbine equipment supplied with this compressor wash system consists of piping from
the purchaser's connection on the base, air operated water injection valve(s), and the appropriate
spray manifold(s). Drains from the inlet plenum, combustion area, exhaust frame, and the exhaust
plenum are also provided. In addition, there are purchaser connections in these drain lines. Refer to
the Water Wash Skid schematic for this on-base equipment.

B. Off–Base Equipment
The off-base portion of the water wash system, known as the water wash skid, contains both a water
tank and a detergent tank. The water tank is equipped with temperature sensors and electric heaters to
maintain proper water temperatures. The skid is equipped with a centrifugal water pump motor
(88TW-1) and a venturi used with the water pump to mix detergent solution. Also included on the
skid are the various control panels to initiate wash and to manually start/stop the appropriate devices.
All equipment is made of corrosion resistant material. Refer to the Water Wash Skid schematic for
this on-base equipment.

All devices are set to give proper temperature, pressure, and flow. The settings for these devices can
be found in the device summary for the corresponding system.

C. Functional Description
During the washing operation, water or wash solution is delivered through customer piping to the gas
turbine in the proper mix ratio. The wash water solution is delivered to the turbine unit at the proper
pressure, temperature, and flow rate to wash the gas turbine compressor. Refer to the system
schematic for proper pressure(s), temperature(s), and flow rate(s) for this gas turbine.

1. System Requirements

Water used for washing turbine parts should be reasonably clean so that it does not cause fouling
or corrosion in itself. Distilled or deionized water is recommended. Water quality requirements
are listed in Table 1 of GEK 111895 (Latest Revision). Oily or varnished oil deposits on internal
gas turbine parts require that a detergent solution be used during the washing operation. The
detergent shall meet the requirements of GEK 111895 (Latest Revision), Appendix 1.

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 5 of 12

F Class Gas Turbine Compressor Water Wash System GEK 111898d

2. Compressor Washing Frequency

The frequency of compressor washing depends upon the severity and type of atmospheric
contamination that fouls the compressor and reduces performance. The recommended method
for establishing the frequency is to monitor gas turbine performance, comparing the routine
performance with the baseline performance to observe the performance trends. If the
performance has fallen significantly, and compressor fouling is suspected, it must be verified by
visual inspection. This visual inspection should include the compressor inlet, bellmouth, inlet
guide vanes and the first and, possibly, the second stage of the compressor blades.

NOTE

Inspection should be made for the source of the oily deposits. If possible, corrective
action should be taken.
D. System Operation
1. General

a. Off-line Water Wash

Off-line water washing should be scheduled during a normal shutdown, if possible. This will
allow enough time for the internal machine temperature to drop to the required levels for the
washing. The time required to cool the machine can be shortened by maintaining the unit at
crank speed. During this cooling of the turbine, the wash water may be heated to the proper
level.

Off-line wash water flow control is accomplished through a manual tuning valve installed in
the off-line supply line, and a local pressure gauge to allow the operator to set the specified
manifold supply pressure.

Refer to the system (MLI 0442) schematic for off-line wash operating parameters.

Refer to GEK 111895 (Latest Revision) for gas turbine compressor liquid washing
recommendations

b. On-line Water Wash (Only if applicable)

The period between off-line water washes can be extended via frequent on-line washing.
When the compressor is suspected of being heavily fouled, an off-line wash should be
performed.

The on–line compressor wash system allows an operator to water wash the turbine
compressor without having to shut down the turbine. The method of washing is similar in
many ways to the off–line system. Both systems use the same pump, 88TW-1, and piping to
supply high quality wash solution to the compressor. When the supply pipe reaches the
vicinity of the turbine base, it splits into two branches, one for the off–line system and one
for the on–line system. Each branch contains a stop valve, flow control orifice, manifold(s)
and spray nozzles.

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 6 of 12

GEK 111898d F Class Gas Turbine Compressor Water Wash System

There are significant differences, though, between the two systems. GE recommends against
the use of detergents during on-line washing, while the use of detergents during off-line
washing are encouraged. The on–line wash water requirements differ from that of off–line
wash solution and must meet the requirements of Table 1 of GEK 111895 (Latest Revision)
for on–line washing. Finally, the on–line system proceeds automatically after it is manually
initiated; whereas, the off–line system requires operator intervention before and after the
wash.

Per the latest on-line wash design improvements, the forward on-line wash manifold has been
removed to minimize the risk of blade root erosion. Therefore, only the outer, aft, manifold is
used during an on-line wash.

Also, the on-line flow control orifice plate has been replaced with a pressure regulator
(VPR74-1). A local pressure gauge is installed on the on-line circuit to make it easy for the
operator to set the specified manifold supply pressure for improved flow control.

In addition, a pressure transducer (96WW-3) is installed on the on-line aft manifold to

measure wash water pressure relative to ambient pressure. This transducer is wired to the
control system to monitor on-line wash water supply pressure.

Refer to the system (MLI 0442) schematic and the device summary for on-line wash
operating parameters and instrument settings and ratings.

NOTE

When using a detergent solution for on–line washing, it is recommended that the
wash be followed by enough rinse water to remove the detergent residue from the
wash nozzles at the spray manifold. This will prevent the detergent solutions from
drying and clogging the nozzles.

c. Grid Frequency Control (Applies to units with GFC requirements only)

Provides water wash injection hardware and control software designed to increase gas turbine
power for grid frequency control (GFC) by spraying water into the compressor inlet. A GFC
circuit is installed parallel to the on-line wash circuit so that both circuits are supplied
simultaneously by the water wash skid. During an extreme under frequency event, two
control valves are commanded open and water flows through both the on-line wash circuit
and GFC circuit for specified time duration. The total flow rate is the same as the maximum
flow capacity of a standard GE water skid, which requires no modification for a GFC
application. To maximize system reliability, a self-test of the GFC circuit is performed for a
few seconds every time that on-line compressor wash is initiated.

Several grid codes specify that at specific frequencies below normal, such as 50 Hz, power
delivered to the grid must meet or exceed a minimum power level. At very low grid
frequencies, water wash injection is used to reduce the net over firing of the gas turbine to
conserve hot section life.

For a GFC installation, the following components are added to on base piping (MLI 0953):
GFC control valve (VA16-4), manual tuning valve, GFC supply line pressure transducer
(96WW-4), GFC water manifold and nozzles with injection on inner cone of inlet plenum
(MLI 1612).

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 7 of 12

F Class Gas Turbine Compressor Water Wash System GEK 111898d

The turbine control includes GFC software (MLI 210) to actuate control valves during an
under frequency event and perform a periodic self-test to verify that supply pressure to the
GFC nozzles exceeds the minimum allowable water pressure.

Refer to the system (MLI 0442) schematic and the device summary for GFC operating
parameters and instrument settings and ratings.

NOTE

Multiple gas turbine sites with GFC typically have a single dedicated water skid for each gas
turbine. Some sites may be equipped with a single water skid that contains one water tank,
one detergent tank, and multiple pumps that supply water to multiple gas turbines. Sites with
the single water skid for multiple gas turbines can only perform an on-line or off-line water
wash to a single gas turbine at a time. Simultaneous water washing of multiple units is not
permitted for the single water skid for multiple gas turbine configurations. However, during
a grid frequency control event multiple water pumps may be simultaneously activated.

2. Mandatory Precautions

Before water washing of the compressor begins, the turbine blading temperature must be low
enough so that the water does not cause thermal shock.

CAUTION

The differential temperature between the washwater and the average of the three turbine
wheelspace temperatures must not be greater than 120°F (67°C) to prevent thermal
shock to the hot gas parts. To support this requirement, the maximum average turbine
wheelspace temperature must be no greater than 150°F (65.6°C) as calculated within the
turbine control system. Reference TIL 1236 “Water Wash Recommendations” for
additional details.

To reduce this difference, the wash water may be heated and the turbine kept on crank until the
wheelspace temperatures drop to an acceptable level. The wheelspace temperatures are read in
the control room.

CAUTION

If, during operation, there has been an increase in exhaust temperature spread above the
normal 15°F to 30°F (8.3°C to 16.6°C), the thermocouples in the exhaust plenum should
be examined. If they are coated with ash, the ash should be removed. Radiation shields
should also be checked. If they are not radially oriented relative to the turbine, they
should be repositioned per the appropriate drawing. If the thermocouples are coated with
ash, or if the radiation shields are not properly oriented, a correct temperature reading
will not be obtained.

If neither of the above conditions exists and there is no other explanation for the temperature
spread, consult the General Electric Service Engineering representative.

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DWG Number GEK111898 Rev D Released 1/31/2014 Page 8 of 12

GEK 111898d F Class Gas Turbine Compressor Water Wash System

WARNING

THE WATER WASH OPERATION INVOLVES WATER UNDER HIGH–

PRESSURE. CAUTION MUST BE EXERCISED TO ENSURE THE
PROPER POSITIONING OF ALL VALVES DURING THIS
OPERATION. SINCE THE WATER MAY ALSO BE HOT, NECESSARY
PRECAUTIONS SHOULD BE TAKEN IN HANDLING VALVES, PIPES,
AND POTENTIALLY HOT SURFACES.

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GEK 111898d F Class Gas Turbine Compressor Water Wash System

NOTE

Before water washing the compressor, inspect the inlet plenum and gas turbine
bellmouth for large accumulations of atmospheric contaminants that could be
washed into the compressor. The deposits can be removed by washing with a
garden hose.

II. FALSE START DRAIN SYSTEM (APPLIES TO DUAL FUEL UNITS ONLY)

The purpose of the False Start Drain System (FSD) is to remove fuel oil or other liquids from the
combustion, compressor discharge, turbine, and exhaust sections while the unit is shutdown and during
startup sequence.

The False Start Drain valves are instrument air operated with open and closed limit switches. The liquid
fuel from the combustion cans will drain from a common header for the lower combustion cans through
the False Start Drain valve (VA17-1). The position of this valve is controlled by a solenoid valve
(20TFD-1). The limit switches (33TFD-1 and 33TFD-2) are used to verify valve position. The other False
Start Drain valves (VA17-1B, VA17-2, VA17-6A, VA17-6B, and VA17-7) are controlled by a single
solenoid (20TFD-2). Open and closed limit switches on each of these valves (33TFD-5, 33TFD-6,
33TFD-7, 33TFD-8, 33TFD-9, 33TFD-10, 33TFD-12, 33TFD-13, and 33TFD-14) are used to verify
valve position.

Refer to TIL 1575-R1 for operational parameters and recommended checks.

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F Class Gas Turbine Compressor Water Wash System GEK 111898d

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GEK 111898d F Class Gas Turbine Compressor Water Wash System

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DWG Number 145E4542 Rev - Released 10/23/2012 Page 2 of 2

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 1 of 28

GEK 111895E

g
Revised, October 2012

GE Energy

F-Class Gas Turbine Compressor Washing

Liquid Washing Recommendations for Gas Turbines with Pulsed
Water Wash Systems

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
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without prior permission of the copyright owner.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 2 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 3 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

TABLE OF CONTENTS

I. SCOPE...................................................................................................................................................4
II. INTRODUCTION.................................................................................................................................4
III. TYPES OF FOULING..........................................................................................................................4
IV. METHODS OF DETECTION..............................................................................................................5
A. Visual Inspection ..............................................................................................................................5
B. Performance Monitoring ...................................................................................................................5
V. WATER WASH RESULTS..................................................................................................................6
VI. ON-LINE WATER WASHING METHOD .........................................................................................6
VII. ON-LINE WATER WASH TECHNICAL REQUIREMENTS ..........................................................7
VIII. ON-LINE WATER WASH ALLOWABLE CONDITIONS ...............................................................8
IX. ON-LINE WASHING AND RESTORATION.....................................................................................8
A. Preparation .......................................................................................................................................8
B. On-Line Washing Procedure .............................................................................................................8
X. OFF-LINE WATER WASHING METHOD .......................................................................................9
XI. OFF-LINE WATER WASH TECHNICAL REQUIREMENTS.......................................................10
XII. OFF-LINE WATER WASH ALLOWABLE CONDITIONS............................................................11
XIII. OFF-LINE WASHING AND RESTORATION.................................................................................12
A. Preparation .....................................................................................................................................12
B. Off-Line Water Wash System Preparation.......................................................................................14
C. Off-Line Washing Procedure...........................................................................................................15
D. Restoration .....................................................................................................................................19

APPENDIX

I. SCOPE.................................................................................................................................................24
II. REQUIREMENTS..............................................................................................................................24
III. MATERIAL COMPATIBILITY........................................................................................................24
IV. TESTS .................................................................................................................................................24
A. Ash content: preparation of test samples..........................................................................................24
B. Accelerated storage stability (from MIL–C–85704A) ......................................................................25
C. Procedure........................................................................................................................................25
V. CUSTOMER SUPPLIED NON-GE WATER WASH SKID.............................................................26

LIST OF FIGURES

Figure 1. Recommended MPG Concentrations – OFWW................................................................................11

LIST OF TABLES

Table 1. Quality Specification.........................................................................................................................22

Table 2. Approximate Water Usage During Compressor Washing...................................................................23
Table A1. Chemical Content of Washing Detergent ........................................................................................25

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 4 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

I. SCOPE

The scope of this document is to present the methods of compressor washing approved by General
Electric. Two methods of liquid washing are employed on–line and off–line. On–line washing is the
process of injecting water into the compressor while the unit is running. Off–line washing is the process
of injecting cleaning solution into the compressor while the unit is rotating at part speed. The advantage
of on–line washing is that it can be done without having to shut down the machine. On–line washing
however, is not as effective as off–line washing, and therefore is used to supplement off– line washing,
not to replace it.

This document applies to all gas turbine models offered by GE Energy, which have the capability to
perform a pulse mode off–line water wash.

NOTE
It is recommended that each customer create a unit-specific procedure and
checklist. The procedure and checklist should include configuring the unit for water
washes, performing the wash and restoration following the wash. These procedures
should conform to the enclosed general guidelines. It is recommended that the
customer include a specific valve line–up before, during, and after the wash in their
procedure. General Electric can provide technical assistance in preparing the
unit-specific procedures and checklists.

II. INTRODUCTION

A loss in gas turbine performance attributable to compressor fouling can be detected by a decrease in
power output and an increase in both heat rate and fuel consumption. The loss of performance is a direct
result of fouling of the axial flow compressor. Fouled compressors result in reduced airflow, lower
compressor efficiency and a lower compressor pressure ratio.

Compressor washing will assist in removing the fouling deposits and restoring performance. It should be
noted that full power may not always be regained if significant fouling has occurred. Regular compressor
washing will help maintain performance as well as allowing each wash to be more effective. Specific
intervals shall be determined based on customer performance and site conditions. Compressor washing
may also slow the progress of corrosion, thereby increasing blade life and reducing the contribution of
corrosion products to the formation of fouling deposits.

III. TYPES OF FOULING

The type and rate of fouling of an axial compressor depends on the environment in which it operates and
the inlet filtration present. Experience has shown that fouling deposits consist of varying amounts of
moisture, oil, soot, water-soluble constituents, insoluble dirt and corrosion products of the compressor
blading material. Fouling deposits are typically held together by moisture and oil. If corrosion of the
blading is occurring, the corrosion products will promote and stabilize the deposit.

It is important to minimize fouling deposits by reducing oil leaks and the ingestion of oily constituents
(lube oil fumes). Good filtration may greatly reduce fouling. Moisture formation cannot be reduced in
humid environments. Moisture is formed in the compressor inlet when humid air is cooled below its dew
point as a result of being accelerated to about Mach = 0.5. GER 3601, “Gas Turbine Compressor
Operating Environment and Material Evaluation” discusses the factors influencing compressor fouling
and corrosion.
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DWG Number GEK111895 Rev E Released 8/15/2013 Page 5 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

IV. METHODS OF DETECTION

GE experience suggests that the rate of performance loss attributable to compressor fouling varies greatly
from site to site and from season to season depending on atmospheric conditions, proximity of the plant
to sources of airborne contaminants, gas turbine usage profile, frequency and duration of online washing,
and overall maintenance practices. Other factors that are often taken into consideration when setting the
frequency of off-line washing include the weekly loading pattern (i.e. is the turbine normally shut down
for weekends), the economic trade-off between a 1-2 day outage for wash versus the extra capacity that is
typically restored, the availability of demineralized water to conduct the wash, and the cost of detergent.

GE experience has indicated a strong correlation between fouling rate and the season of the year, with
little to no losses during the winter season and heavy fouling rates in spring and summer. GE experience
has also shown that periods of frequent rain tend to show less fouling. Considering all the above,
depending on the economics of each plant, it is GE's experience that users who place a high priority on
output capacity and thermal efficiency are advised to regularly monitor their gas turbine performance.
From a thermal performance perspective, it is recommended that the customer perform an off-line water
wash when the loss in gas turbine performance attributable to the compressor reaches the 2-3 % level
between off-line washes. The performance loss attributable to the compressor can be determined through
regular measurement and monitoring of the compressor flow rate and compressor efficiency, with special
care to normalize the data to a common operating condition. In general, each 1% loss in flow or
efficiency is equivalent to approximately 1% loss in turbine power.

From a compressor long-term durability and operability standpoint, GE recommends that the compressor
flow rate be monitored over time and the compressor be subjected to an off-line wash to prevent the flow
rate from decreasing more than 5% relative to new and clean levels.

There are two basic methods for determining the cleanliness of the compressor, visual inspection and
performance monitoring. Both of these are described below.

A. Visual Inspection
Visual inspection involves shutting the unit down, removing the inlet plenum inspection hatch, and
visually inspecting the compressor inlet, bell mouth, inlet guide vanes and early stage blades.

If any deposits, including dust or filmy deposits, can be wiped or scraped off these areas, the
compressor is fouled sufficiently to affect performance. The initial inspection also reveals whether
the deposits are oily or dry. For oily deposits, a water-detergent wash is required. Location of the
source of the oil and correction should be accomplished before washing to prevent recurrence of the
fouling.

If only dry deposits are found, water alone may be sufficient.

B. Performance Monitoring
A second method for detecting a fouled compressor is performance monitoring. Performance
monitoring involves obtaining gas turbine data on a routine basis, which in turn is compared to base
line data to monitor trends in the performance of the gas turbine.

The performance data is obtained by running the units at steady-state BASE load and recording
output, fuel consumption, exhaust temperature, inlet air temperature, inlet air humidity, barometric
pressure, inlet system pressure drop, bellmouth pressure, compressor discharge pressure and

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 6 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

temperature. The data should be taken carefully with the unit warmed up and running under normal
steady state operating conditions.

GEK 107551 “Standard Field Performance Testing Philosophy” can be used as a guide for assessing
machine performance both before and after cleaning the compressor. The purpose of this particular
document is to establish the performance of generator drive machines. GEK 111517 is the equivalent
document for mechanical drive applications. Note that these GEK's are designed to measure the
overall performance of the unit, namely output and heat rate. Additional measurements and
calculations are necessary, as indicated in the preceding paragraph, to also directly measure and
monitor the compressor flow and efficiency. The computation of compressor flow and efficiency can
be accomplished by using standard thermodynamic principles.

Output and heat rate can be corrected to a standard condition using the turbine performance curves,
and an analysis may be made of compressor flow, pressure ratio and efficiency. The current
performance levels can be compared to base line data and will aid in determining the extent to which
the compressor has become fouled.

If performance analysis indicates compressor fouling, it should be verified by a visual inspection.

V. WATER WASH RESULTS

After cleaning, there should be a noticeable increase in performance based on the site conditions and gas
turbine models. Increase in performance is a function of how fouled the compressor was initially. An
increase in BASE load power of 5 % is not uncommon following an off-line wash. This can be confirmed
by comparing restored performance data to levels of performance before washing, utilizing the procedure
in GEK 107551 for generator drive machines and GEK 111517 for mechanical drive applications as
previously described under Section IV (Performance Monitoring). It should be noted that full power
might not always be regained once significant fouling occurs. Regular compressor washing will help
maintain performance. Specific intervals must be determined based on customer performance.

VI. ON-LINE WATER WASHING METHOD

The intent of on-line washing is to extend the period between off-line washes through frequent washings
of short duration. When the compressor is suspected of being heavily fouled, an off-line wash should be
performed.

GE does not recommend the use of detergents during on-line washing because there is a concern for
leaving detergent residue on the latter stages of the compressor. The detergent effectiveness during an
on-line wash is limited since there is no soak period as with the off-line wash. As the on-line washing
practice has been found to be most effective when carried out daily, the specification on the liquid must
be more restrictive for on-line washing than off-line washing.

In the past, on-line water washing may have resulted in a fogging over of flame detector lenses, based on
the type of flame detector, gas turbine model, and combustion system. Operating experience has shown
that this is not a problem with DLN 2.0, 2.0+, 2.6 and 2.6+ combustion systems. It is noted that the
on-line wash may result in unacceptable emission output levels during the washing cycle.

Adding water for wash will increase the compressor pressure ratio and thus reduce the surge margin.
Under normal circumstances, there is ample surge margin to allow for washing and steam or water
injection for NOx control or power augmentation.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 7 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

VII. ON-LINE WATER WASH TECHNICAL REQUIREMENTS

The following technical requirements must be met to conduct an on-line water wash from the water wash
skid and to interface with the turbine control panel:

1. Water used for On-line Water Washing must meet the Quality Specification of Table 1.
2. Water Wash Skid outlet shall meet the flow, pressure, and temperature requirements defined in the
Piping Schematic Diagram (MLI 0442).
3. The initial setting of the supply pressure and thus flow to the on-line spray nozzles shall be properly
adjusted by the customer. During on-line water wash operation, adjust the pressure regulator
VPR74-1 to the required pressure requirements as established by the Piping Schematic Diagram
(MLI 0442). The following procedures can be followed to compensate for head pressure difference
between the pressure gauge and engine centerline.

a. Pressure “P” can be determined at site using the following equation,

b. P = 80 PSIG + 0.43 x A,

c. Where: A = B – C, Which is the elevation difference between engine centerline and gauge
centerline in feet.

d. Dimension “B” is found on MLI 0306 (Mechanical Outline Drawing).

e. Dimension “C” is site specific and can be determined at site by measuring from the centerline of
the pressure gauge to the equipment base line.

4. Prior to installing the on-line nozzles and using the water wash system for the first time in the field, a
preliminary flushing procedure shall be performed on the water wash supply lines to free the system
of burs, dust, weld fragments, etc. The flushing recommendations may be found in 363A4220,
“Water Washing Flushing Procedure.”
5. The Turbine Control Panel shall cycle valve VA16–3, via solenoid driver 20TW–6. The valve will
open and close during the on-line water wash cycle.
6. Interface points from the Water Wash Skid or MLI 0461, shall be checked at a minimum for the
following:

a. Piping connection to Purchaser Connection WW1 on MLI 0442.

b. Contact output from turbine control panel to water wash skid, which shall identify start/stop of
pump during wash cycles.

c. Contact output from water wash skid to turbine control panel, indicating water flow to turbine.

d. Control output from water wash skid to turbine control panel indicating a trouble.

If a customer or AE provides the water wash skid, then the party providing the skid shall be responsible
for the proper function and operability of the water wash skid.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 8 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

VIII. ON-LINE WATER WASH ALLOWABLE CONDITIONS

For on-line water wash, the operator must take appropriate precautions to prevent freezing in the
compressor inlet, gas turbine, and exhaust and drain systems. An on-line water washing permissive does
not permit on-line water washing when compressor inlet temperature (CTIM), is less than 50°F (10°C).

CTIM must be measured when inlet bleed heat is off. In no circumstance shall the operator force inlet
bleed heat on, to satisfy this on-line water wash operating permissive.

In addition to meeting this CTIM permissive, the IGV angle must be greater than 70 degrees to help
decrease the risk of icing and icing damage due to increased pressure drop across the IGVs.

For the 7FA.05 Gas Turbine: 1) the use of IBH to meet the CTIM criteria above is allowed. 2) The IGV
angle must be less than 15 degrees. Note: for the 7FA.05, a smaller IGV angle is more open.

Environmental Health and Safety issues arising from the choice to perform an on-line water wash will fall
directly within the customer’s ownership and responsibility to comply with all federal, state or local
governing requirements. The customer should recognize that the injection of water into the compressor
inlet during on-line washing could result in exceeding site operating permit Clean Air Act emission
requirements. If operating permit emission requirements are exceeded, a permit variance should be
considered.

IX. ON-LINE WASHING AND RESTORATION

A. Preparation

1. Water used for On-line Water Washing must meet the Quality Specification of Table 1.

2. Turbine must be running and not in the process of shutting down.

3. Compressor inlet temperature, CTIM, must be greater than 50°F (10°C). Refer to Section VIII
“On-Line Water Wash Allowable Conditions.”

4. On-line water washing should not be performed while inlet bleed heat is operating for any
reason. Do not force inlet bleed heat off to satisfy this on-line wash requirement.

5. The minimum IGV angle to perform on-line water wash must be greater than 70 degrees. (Less
than 15 degrees for 7FA.05)

B. On-Line Washing Procedure

1. Once all permissives are satisfied, the operator is to select ON-LINE WATER WASH ON push
button (L83WWON_CPB).

NOTE

Selection of ON-LINE WATER WASH ON will not be allowed if a permissive is

not met at any time. ON-LINE WATER WASH ON will have to be reselected once
the fault or permissive is clear.

2. The unit controller will then open the on-line water wash inlet valve VA16–3 and signal the
water wash pump to start.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 9 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

3. If all permissives are met, the on-line wash cycle will begin.

4. The operator can abort the on-line wash at any time by selecting ON-LINE WATER WASH
OFF (L83WWOFF_CPB).

5. At the end of the 15-minute cycle, the on-line wash will automatically select off.

6. The operator can then decide to re-select ON-LINE WATER WASH ON push button
(L83WWON_CPB) for an additional 15-minute cycle if required. A total of 30-minutes are
permitted within a 24-hour window.

7. At the conclusion of the on-line wash, the operator is to select ON-LINE WATER WASH OFF
(L83WWOFF_CPB). The operator can then return the unit to normal service.

NOTE

Performance data has shown that a 15-minute cycle is as effective as a 30-minute

cycle in compressor performance retention. Based upon site performance data, the
customer may decide to initiate the secondary 15-minute cycle. The control
permissive will allow a total of 30-minutes of On-Line washing per 24 hours of
operation. The additional On-Line wash cycle may be conducted at anytime within
this 24-hour permissive.

X. OFF-LINE WATER WASHING METHOD

When the compressor is suspected of being heavily fouled, an off-line wash should be performed. Refer
to Section IV (Methods of Detection) for information on monitoring compressor performance.

GE recommends and encourages the use of detergents for use during off-line water washing. The water
and detergent solution being used during off-line washing shall meet the Quality Specifications in Table
1. The detergent, which may be used for off-line washing, must adhere to the Compressor Washing
Detergent Specification in Appendix 1 of this document.

In general, deposits will contain some water-soluble material and oils. The latter will be more amenable
to removal by detergent, but the deposits may be removable by water washing alone, depending on the
amount of water-soluble material present. Heated water is generally more effective than cold water, but is
not required.

There are a number of detergents commercially available for the purpose of cleaning the compressor,
some of which, along with the deposits that have been removed, may constitute a hazardous solid waste
(as defined by the United States Environmental Protection Agency) when used for water wash. Because
of this possibility, local regulations should be considered for storing, handling and treating of the water
wash effluent when the drain and containment system is designed. Detergents must meet the requirements
specified in Appendix 1.

GE Clean Blade GTC1000 is the recommended water washing detergent given its demonstrated
effectiveness in compressor cleaning. Please contact the local General Electric field representative for any
requests related to water washing and water wash detergents.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 10 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

XI. OFF-LINE WATER WASH TECHNICAL REQUIREMENTS

The following technical requirements must be met to conduct an off-line water wash from the water wash
skid, to interface with the turbine control panel:

1. Off-line washing solution must meet the Quality Specification of Table 1 and the detergent
concentrate must meet the requirements of Appendix 1.
2. Water Wash Skid outlet shall meet the flow, pressure, and temperature requirements defined in the
Piping Schematic Diagram (MLI 0442).
3. The initial setting of the supply pressure and thus flow to the off-line spray nozzles shall be properly
adjusted by the customer. During off-line water wash operation, the customer is to adjust the manual
tuning valve to the required pressure requirements as established by the Piping Schematic Diagram
(MLI 0442). The following procedures can be followed to compensate for head pressure difference
between the pressure gauge and engine centerline.
4. Pressure “P” can be determined at site using the following equation, P = 85 PSIG + 0.43 x A, Where:
A = B – C, Which is the elevation difference between engine centerline and gauge centerline in feet.

a. Dimension “B” is found on MLI 0306 (Mechanical Outline Drawing).

b. Dimension “C” is site specific and can be determined at site by measuring from the centerline of
the pressure gauge to the equipment base line.

5. Prior to installing the off-line nozzles and using the water wash system for the first time in the field,
a preliminary flushing procedure shall be performed on the water wash supply lines to free the
system of burs, dust, weld fragments, etc. The flushing recommendations may be found in
363A4220, “Water Washing Flushing Procedure.”
6. Prior to initiating the off-line water wash, the bell mouth, struts, and IGV’s should first be hand
cleaned to prevent these deposits from being washed into the compressor during the cleaning. Refer
to procedure 361A6297, “Water Washing Hand Cleaning Procedure.”
7. The Turbine Control Panel shall be cycling valve VA16–1, via solenoid driver 20TW–4. The valve
will open and close during the off-line water wash and rinse cycles.
8. Interface points from the Water Wash Skid or MLI 0461, shall be checked at a minimum for the
following:

a. Piping connection to Purchaser Connection WW1 on MLI 0442.

b. Contact output from turbine control panel to water wash skid, which shall identify start/stop of
pump during wash cycles.

c. Contact output from water wash skid to turbine control panel, indicating water flow to turbine.

d. Control output from water wash skid to turbine control panel indicating a trouble.

If a customer or AE provides the water wash skid, then the party providing the skid shall be responsible
for the proper function and operability of the water wash skid.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 11 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

XII. OFF-LINE WATER WASH ALLOWABLE CONDITIONS

For off-line water wash, the operator must take appropriate precautions to prevent freezing in the
compressor inlet, gas turbine, exhaust and drain systems. Off-line water washing shall not be performed
when compressor inlet temperature (CTIM) is less than 40°F (4°C), measured while cranking.

In conditions where CTIM is between 40°F (4°C) and 14°F (-10°C), an antifreeze agent can be added to
the water solution in the holding tank to prevent freezing during an off-line wash. At present, the only
acceptable antifreeze agent is Monopropylene Glycol (MPG). MPG has several beneficial characteristics
that make it the preferred choice. MPG is non-toxic and friendly to the environment. MPG is
non-hazardous with a high flash point so it is safe, easy to handle, and store. MPG has a high boiling
point and a low evaporation rate, which means that the freeze point can be maintained over a long time
period. Other antifreeze agents are not permitted as they may attack the titanium and other metals in GE
heavy-duty gas turbines. Recommended antifreeze mixtures for MPG are tabulated in Figure 1.
Monopropylene Glycol (MPG) must meet the Industrial Standards for Deicing / Anti-Icing Fluids as per
AMS 1424. Any other antifreeze agent considered must be submitted for review and approval.

NOTE

Contact your local GE representative for assistance or for additional information for
support in changing off-line water wash CTIM minimum temperature permissive, if
cold climate off-line water washing is going to occur.

Environmental Health and Safety issues arising from the choice to use an antifreeze solution will fall
directly within the customer’s ownership and responsibility to comply with all federal, state or local
governing requirements. The provided MPG concentrations have been found to be compatible with the
materials of the gas turbine, in addition to having no adverse impact on the performance of the machine.

NOTE

The water-detergent and antifreeze solution shall be a homogeneous mixture when

sprayed into the gas turbine. Please note, that GE does not maintain any program to
ensure that the detergent suppliers listed in Section X are compatible with MPG. As
such, it is the responsibility of the customer to consult with their local supplier if
agitation is required and to ensure that the water-detergent and antifreeze solution is
in compliance with the recommended concentrations.

Recommended MPG Concentration vs. CTIM

MPG Antifreeze H2O

CTIM°F (°C)
% Vol % Vol

+14 to +40 (-10 to 4) 36 64

Figure 1. Recommended MPG Concentrations – OFWW

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 12 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

XIII. OFF-LINE WASHING AND RESTORATION

A. Preparation
The intention of this portion of this recommendation is to isolate all air extraction points and drain all
low points to prevent water wash effluent from entering the piping systems. General Electric
recommends that all piping, which may come in contact with water, have a continuous slope to a
drainable low point without traps. It is recognized that additional isolations and drains may be
required depending on specific systems, equipment, customer supplied equipment and interconnect
piping. It should be further recognized that valve and control logic nomenclature might vary. It is
recommended that the customer develop a customized checklist for the preparation and restoration of
the gas turbine for an off-line water wash, especially a valve line-up before, during and after a wash.
The approximate volume of drain water collected during a complete off–line wash cycle can be found
in Table 2.

1. For off-line water wash, even with the water inlet temperatures within the GE recommended
parameters, the average of the three turbine wheelspace temperatures must be stabilized at 150°F
(65.6°C) or lower, while measured at speed of 30 RPM or lower, before water wash is started.
For units that are not equipped to attain a stable speed of 30 RPM or lower, the average
wheelspace temperature must be stabilized at 130°F (54.4°C) or lower while measured at
60 RPM or lower, before the wash is started. Contact your local GE representative for assistance
or for additional information. Reference the current revision of TIL 1236 “Water Wash
Recommendations” for further details.

2. If the unit is equipped with off-base atomizing air compressor(s), the operating compressor
should be de-energized during the pulse mode water wash cycle.

3. If necessary, close flame detector valves or blank-off, based on both the type of flame detector
and gas turbine model. Water may foul the flame scanners and make start-up difficult.

4. Fuel manifold low point drains are to remain closed during the pulse mode wash cycle. Open at
the end of the rinse cycle, prior to the start of the drying cycle to ensure that no water is present
in the manifold(s).

5. Manually isolate systems, open drains and divert drains as follows:

● The flow through the false start drain valves must be diverted from the sludge tank to a water
wash effluent tank on turbines that operate on liquid fuel or have the capability to do so. On
gas-only machines there may be no false start drain valves, only manual water wash drain
valves.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 13 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

NOTE
The false start drain flow or any flow that goes normally to the sludge tank must be
diverted from its “normal” path into the sludge tank to the water wash effluent drain
system to prevent an overflow of the sludge tank. In addition, the false start drain
effluent should be visible to evaluate the effectiveness of the wash cycle.
● Open the inlet plenum water wash drain valve at or near the bottom of the inlet plenum.
● Open the water wash drain valve(s) in the combustion chamber water wash drain header as
well as the water wash drain valve in the manway cover.
● Close the isolation valve in the gas vent line off of the false start drain header, if applicable.
● For gas-only machines, open the main water wash drain valves in the turbine shell and
exhaust frame drains.
● Close valve installed in the AD–2 lines (MLI 0417) supplying compressor discharge air to
the false start drain valves, if applicable, and open downstream drain.
● Switch motor controller for the turbine exhaust frame-cooling fan motors, 88TK–1 and
88TK–2 in the manual “ON” position, if provided.
● Open the exhaust plenum water wash drain valve at or near the bottom of the exhaust
plenum.
NOTE
This step is necessary to prevent wash water from entering the exhaust frame
cooling system during the wash cycle.

6. The atomizing air system (refer to MLI 0425), if provided, is to be isolated in the following
manner:

● Close isolation valve on the inlet side of the atomizing air system from AD–8 line.
● Open atomizing air separator drain valve, if provided.

7. The cooling and sealing air circuitry (refer to MLI 0417) is isolated in the following manner:

● Close isolation valves in AE–9 and AE–13 lines. Open all low point drains just upstream of
these isolation valves (CA52 and CA53).
● Close valves in all compressor discharge pressure transducer supply lines (AD–4), if
provided.
● Close isolation valve upstream of AD–6. Open low point drain (CA54) on inlet side of
AD–6, if provided.
● Close isolation valves to AD–1, 3 and if provided, AD–5, AD–7, AD–10, AD–11 lines.
● Close isolation valve on the inlet side of the gas purge system from PA3 line, if provided.
● Close valve in bearing sealing air supply line AE–5 from air extraction, if provided.

8. The inlet heating system (refer to MLI 0432), if provided, is isolated in the following manner:

● Close VM15–1 manually, or if motorized valve is provided, ensure it is closed.

● Open low point drain (CA20) in interconnecting piping.
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DWG Number GEK111895 Rev E Released 8/15/2013 Page 14 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

CAUTION

If any water wash valve is difficult to actuate, or personnel suspect that the valve
integrity may be compromised, then the valve should be inspected, cleaned,
maintenanced, or replaced as needed to return the valve to proper function. Failure to do
so may result in leakages which could cause damage to the turbine and/or equipment.

B. Off-Line Water Wash System Preparation

The following steps shall be performed on the water wash skid (if provided by General Electric) prior
to initiating the off-line water wash. It is required that prior to initiating the off-line water wash, the
following procedures be conducted. This procedure will help ensure that both the supply line is
flushed of possible debris and that water is present in the line upstream of VA16–1 in preparation for
the off-line water wash cycle.

CAUTION

If an antifreeze agent is being added, be sure that the water wash supply system is full of
antifreeze mixture prior to initiating the wash cycle. This will prevent freezing and
possible formation of foreign object damage.

1. Turn on the skid breaker panels.

2. Set the HANDS/OFF/AUTO switch in the AUTO position in order to enable starting of the skid
pump 88TW–1 via the PLC.

PLC on the skid will check skids required parameters.

3. On the Turbine Main Control Display Screen, place the Master Select Switch in the CRANK
position. Select the Water Wash Control User Defined Display on the turbine control panel CRT.
Select OFF-LINE WATER WASH ON (L43Bwon_CPB).

At this time, the turbine is prohibited from firing.

4. Place the 3-way customer supplied (if applicable) valve upstream of PC WW1 to the drain
position.

5. Set the HANDS/OFF/AUTO switch in the HANDS position, which shall manually start the wash
skid motor/pump. Allow the pump to run for the appropriate time required for flushing (each site
may have a different time based on the pump flow and piping arrangement).

6. When steady water is present at the drain port of the 3-way valve per visual inspection, return the
HANDS/OFF/AUTO switch in the AUTO position.

7. Return the 3-way valve to the normal position.

C. Off-Line Washing Procedure

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 15 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

At this point, the system is set to commence the off-line water wash.

From the Main Control Display, initiate a turbine START signal. This command will crank the
turbine to water wash speed via the LCI once the temperature permissives (wheelspace and inlet
temperatures) have been met.

When cranking speed and no flame detection signals are detected, the IGV’s will go to 75 degrees
open position. The IGV’s will remain at this position throughout the wash cycle. The sequencing will
now initiate the pre-wash cycle. For 7FA.05, The IGV will go to 10 degrees open position.

A pre-wash cycle will be initiated in order to flush all the loose contaminates such as dust and dirt
from the compressor prior to applying detergent during the detergent cycle. This is a water only
application, which reduces the amount of dirt particles that may become entrained in the detergent
foam.

NOTE

The pulse mode sequencing shall operate solenoid valve 20TW–4 such that the air
actuated valve, VA16–1 is open during the pre-wash pulse and all other pulses that
follow. Likewise, 20TW–4 shall close VA16–1 between pulses.
At the conclusion of the pre-wash cycle, the supply piping should be pre-filled with
a water/detergent mixture in preparation for the detergent injection cycle. This
procedure ensures that both water and detergent are present in the line upstream of
VA16–1 prior to initiating this sequence of the washing cycle.

1. Place the 3-way customer supplied (if applicable) valve upstream of PC WW1 to the drain
position.

2. On the water wash skid, place the normally closed ball valve upstream of the venture, in the
detergent supply line, to the open position.

3. Set the HANDS/OFF/AUTO switch in the HANDS position, which shall manually start the wash
skid motor/pump. Allow the pump to run for the appropriate time required for flushing (each site
may have a different time based on the pump flow and piping arrangement).

4. When a consistent water/detergent mixture is present at the drain port of the 3-way valve per
visual inspection, return the HANDS/OFF/AUTO switch in the AUTO position.

5. Return the 3-way valve to the normal position.

6. The water wash control logic will be in a hold position. After the previous step has been
completed, select CONTINUE WASH push–button (L43DET_CPB).

The detergent/water solution will be injected into the unit during the wash cycle(s) followed by the
appropriate soaking period between the wash cycle(s).

At the conclusion of the soaking period, the customer supplied piping shall be flushed with water
prior to rinsing via the following steps.

NOTE

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 16 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

These steps are important in preventing detergent from entering the off-line
manifold during the rinse cycle(s).

7. Place the 3-way customer supplied (if applicable) valve upstream of PC WW1 to the drain
position.

8. On the water wash skid, place the normally closed detergent ball valve upstream of the venture,
in the closed position.

9. Set the HANDS/OFF/AUTO switch in the HANDS position, which shall manually start the wash
skid motor/pump. Allow the pump to run for the appropriate time required for flushing (each site
may have a different time based on the pump flow and piping arrangement).

10. When only water without detergent is present in the off-line water wash supply line, return the
HANDS/OFF/AUTO switch in the AUTO position.

11. Return the 3-way valve to the normal position.

The previous steps ensure that only water is allowed to enter the unit during the rinse cycle. The
object of the rinse cycle(s) is to remove detergent from the surface areas of the compressor blades and
to rinse the remainder of the unit.

12. The rinse cycle(s) will begin when the operator selects the RINSE Push-Button
(L43RINSE_CPB).

After completing the initial rinse cycle, the operator will have the choice to select an additional rinse
cycle via PULSE Push-Button (LOFL_XTR_CPB) or END RINSE CYCLE Push Button
(LOFL_END_CPB). If the operator elects to choose additional rinse cycles, the choice exists to add a
rinse cycle to make sure that the unit is free of detergent/contaminants. The Rinse Mode will be
terminated when the operator selects the END RINSE CYCLE Push-Button (LOFL_END_CPB).

NOTE

When possible, it is suggested that a drain conductivity measurement be made at

the WW33 drain connection from the combustor. This method is an alternative to a
visual observation of the amount of foam that is present in the drain. It is expected
that the number of rinse cycles will be reduced when based on a drain conductivity
measurement as compared to a visual inspection.
For a demineralized water supply, the expected conductivity measurement is close
to 1.0 microSiemans/cm.
The recommended criteria for WW33 drain conductivity measurements are listed
below:

a. Goal is to plot the trend of conductivity vs. number of rinse cycles and determine the point
when the curve flattens out below specified limit.

b. To declare rinse complete, the difference in conductivity between supply demineralized

water and WW33 drain shall be less than 5 microSiemans/cm for an interval of 5 rinse
cycles.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 17 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

13. After completing the rinse cycle(s), an operator will stop the unit by selecting the STOP
push-button off of the Turbine Control Panel interface display. This will allow the unit to coast
down to turning gear speed to drain any remaining water in the unit.

14. The WATER WASH OFF Push Button (L43BWOFF_CPB) should be selected at this time from
the Turbine Control Panel interface display.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 18 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

***DANGER***

WHEN OPENING THE LOW-POINT DRAINS DURING THE DRYING

CYCLE, STAGNANT FUEL GAS WILL BE PURGED INTO THE
TURBINE COMPARTMENT. STEPS 15 – 17 HAVE BEEN INCLUDED
TO MITIGATE THE POTENTIAL DANGERS THIS COULD POSE TO
SITE PERSONNEL.

15. Ensure that the stop-ratio valve (SRV), auxiliary stop valve, and gas control valves (GCV’s) are
closed and that the valve controlling the venting of the P2 cavity is open. Further, maintain
site-safe work practices and ensure that all appropriate lock-out, tag-out procedures are
performed on these valves.

16. Ensure that the hazardous gas sensors and the compartment ventilation fans are operational.

17. Open the Gas Fuel manifold low point drains. Prior to initiating the Water Wash drying cycle,
ensure that all site personnel are outside of the turbine enclosure with all personnel access doors
closed.

18. Bring the unit up to cranking speed for the drying cycle. Drying cycle duration is 20 minutes.
The drying cycle is designed to remove any residual water left in the unit that has yet to drain
out. A Master Reset may be required before selecting START again.

NOTE

It is preferred that the unit run at FSNL for a minimum of 10 minutes within 24
hours of conducting an off-line water wash to ensure any remaining water is
removed from within the unit. If firing the unit is not a viable option following an
off-line water wash, it is recommended that the crank speed drying cycle be
extended to 40 minutes as an alternative to ensure proper drying of the unit.

CAUTION

If an antifreeze agent is being used the unit shall be fired and operated at FSNL (full
speed no load) for a minimum duration of 10 minutes to dry the unit and prevent
possible formation of foreign object damage. A normal start and load cycle will satisfy
this requirement.

19. At the end of the 20-minute drying cycle, an operator will have to visually check the various
off-line water wash drain ports on the gas turbine to ensure that no water wash effluent is
flowing out of the unit. All water wash low point drains should be open at this time including all
low point drains in the gas fuel, atomizing air system, inlet bleed heat and purge systems to
ensure that no water has entered these systems. Once it has been confirmed that no water is
draining from the unit, the drying cycle can be brought to a close by initializing a turbine STOP
signal.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 19 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

NOTE

In the event of an aborted water wash, the unit shall not be re–started until the full
rinse and drying cycle is completed.

20. To end the off-line water wash drying cycle, select the OFF Push-Button from the turbine control
panel interface display. This step terminates your Off-line Water Wash.

D. Restoration
Return the following items and manual valves to their previous position in the order listed.

1. Open the hand valves or remove blank-off plates on flame detectors, if applicable.

2. If applicable, set off-base atomizing air compressor motor to AUTO.

3. The flow through the false start drain valves must be diverted back from water wash effluent
tank to the sludge tank on turbines that operate on liquid fuel or have the capability to do so (not
applicable to gas-only machines).

CAUTION

It is important that the line that allows waste fuel to drain to the sludge tank be kept open
after water washing and during normal turbine startup and operation, so that fuel or
water, which may accumulate in the exhaust plenum, can continuously drain out of the
plenum. Accumulation of waste fuel in the exhaust plenum is potentially hazardous.

4. Close the inlet plenum water wash drain valve at or near the bottom of the inlet plenum.

5. Close the water wash drain valve(s) in the combustion chamber water wash drain header as well
as the water wash drain valve in the manway cover.

6. Open the isolation valve in the gas vent line off of the false start drain header, if applicable.

7. For gas-only machines, close the main water wash drain valves in the turbine shell and exhaust
frame drains.

8. Open valve installed in the AD–2 lines (MLI 0417) supplying compressor discharge air to the
false start drain valves, if applicable, and close downstream drain.

9. Switch the motor controller for the turbine exhaust frame cooling-fan motors, 88TK–1 and
88TK–2 in the manual “AUTO” position, if provided.

10. Close the exhaust plenum water wash drain valve at or near the bottom of the exhaust plenum.

11. The atomizing air system, if provided, is to be restored to the normal start-up and running mode
in the following manner:

● Close all low point drains in the atomizing air lines.

● Open isolation valve on the inlet side of the atomizing air system from AD–8 line.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 20 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

CAUTION

It is critical that this valve be opened to prevent damage to the turbine.

12. Close atomizing air separator drain valve, if provided.

13. Open isolation valve on the inlet side of the gas purge system from PA3 line, if provided.

CAUTION

It is critical that this valve be opened to prevent damage to the turbine.

14. The cooling and sealing air circuitry is reengaged in the following manner:

● Open manual isolation valves in AE–9 and AE–13 lines.

CAUTION

It is critical that the 9th and 13th stage extraction valves are open prior to firing the unit in
order to prevent damage to the turbine.

● Close all low point drains just upstream of these isolation valves in lines AE–9 and AE–13
(CA52 and CA53).
● Open valves in all compressor discharge pressure transducer supply lines (AD–4), if
provided.

CAUTION

It is critical that these valves be completely opened to prevent damage to the turbine.

● Open isolation valve upstream of AD–6, if provided.

CAUTION

In configurations where AD–6 is used to supply gas purge, it is critical that this valve be
completely opened to prevent damage to the turbine.

● Close low point drain (CA54) on inlet side of AD–6, if provided.

● Open isolation valves to AD–1, 3 and if provided, AD–5, AD–7, AD–10, AD–11 lines.
● Close valve in bearing sealing air supply line AE–5 from air extraction, if provided.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 21 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

CAUTION

It is critical that this valve be opened to prevent damage to the turbine.

15. The inlet heating system, if provided, is restored to the normal start-up and running mode in the
following manner:

● Open VM15–1 manually, or if motorized valve is provided, ensure it is opened.

● Close low point drain (CA20) in interconnecting piping.
● Close all manifold low point drains opened during drying cycle.
● Close all low point drains in purge, atomizing air, and inlet bleed heat systems if opened
during drying cycle.

NOTE

When the OFF-LINE WATER WASH OFF is selected, the permissive is in place to
allow the unit to fire and the permissive is removed to allow the VA16–1 valve to
be opened.

CAUTION

At the conclusion of water wash operation, all valves must be returned to their proper
position, as identified in the sections above. Failure to do so can cause damage to the
turbine and/or equipment.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 22 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

Table 1. Quality Specification

OFF-LINE WASHING (for water only or detergent and water applications)

TOTAL SOLIDS (dissolved and undissolved) 100 ppm

TOTAL ALKALI METAL 25 ppm

OTHER METALS WHICH MAY PROMOTE 1.0 ppm

HOT CORROSION (i.e. lead, vanadium)

pH (determined by glass electrode) 6.5 to 7.5

*See Table A1 in Appendix 1 for detergent chemical specifications.

ON–LINE WASHING (for water only applications)

TOTAL SOLIDS (dissolved and undissolved) 5 ppm

TOTAL ALKALI AND OTHER METALS WHICH 0.5 ppm

MAY PROMOTE HOT CORROSION

pH (determined by glass electrode) 6.5 to 7.5

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 23 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

Table 2. Approximate Water Usage During Compressor Washing

OFF-LINE WATER WASH TOTALS

Gas Turbine Total Volume Volume of Five Additional Rinse Pulses

71FA and 71FB 1600 gallons 210 gallons

91FA and 91FBA 2300 gallons 300 gallons

ON-LINE WATER WASH TOTALS

Gas Turbine Total Volume

71FA and 71FB 135 gallons

91FA and 91FBA 195 gallons

Total volume represents the minimum volume of water that may be used during a single complete
off-line and on-line compressor wash cycle.

For off-line water wash, the total volume will vary based on the operator’s decision to perform or
bypass additional rinse pulses following the rinse sequencing.

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DWG Number GEK111895 Rev E Released 8/15/2013 Page 24 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

APPENDIX
COMPRESSOR WASHING DETERGENT SPECIFICATION

I. SCOPE
1. This specification is for cleaning compounds for use in compressor washing. It is required that these
compounds will not cause harm to gas turbine components. Thus, their purity and composition must
be such that they do not cause aqueous corrosion or stress corrosion of compressor materials. Also, it
is required that they do not cause hot corrosion in the turbine. Furthermore, they must not lead to
compressor fouling. With regard to the cleaning agents themselves, they must be chemically stable
in themselves and in their mixtures with water. Also, they must not form combustible mixtures and
they should satisfy all local codes relative to health and safety requirements. Compliance with this
specification does not imply a cleaning compound improves the cleaning of a compressor over and
above what can be obtained from water alone.

II. REQUIREMENTS
1. The cleaning compound when mixed with water in the manufacturer’s prescribed concentration shall
satisfy the water washing specifications for off-line water quality given in Table 1. In the pure state
it shall satisfy the specification given in Table A1.
2. The residue or ash content of the cleaning compound shall not exceed 0.01%. See test IV A.
3. The storage stability of the cleaning compound shall show no marked color change, shall not
separate and shall not corrode or stain the steel specimen when tested as specified in test 4.5.16 of
MIL–C–85704A. This test is given in IV B.
4. The cleaner and its mixtures with water shall not form gums under compressor conditions.
5. The Pensky-Martens flash point of the cleaning compound shall be above 140°F (60°C)
(ASTM D93).

III. MATERIAL COMPATIBILITY

1. Use of the cleaning compound shall not have adverse effects on engine system materials such as
compressor or turbine materials.

IV. TESTS
A. Ash content: preparation of test samples
Approximately 10 g of cleaning compound shall be weighed to the nearest 0.1 mg in a tarred
porcelain crucible. The crucible shall be heated at 221° ± 2°F (105° ± 1°C) for 24 hours, then heated
at 464° ± 4°F (240° ± 2°C) for the next 24 hours. Following this, the crucible and its contents shall be
carefully ignited over a Bunsen-type gas burner. The crucible shall then be placed in a muffle furnace
at 1,900°F (1,040°C) for 2 hours. The crucible shall be transferred to a desiccator, cooled and
weighed until constant weight. The ash content shall be calculated as the percentage of the initial
weight of cleaning compound.

24 © 2013 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK111895 Rev E Released 8/15/2013 Page 25 of 28

F-Class Gas Turbine Compressor Washing GEK 111895E

B. Accelerated storage stability (from MIL–C–85704A)

1. Preparation of test sample

A 150-ml portion of a well-shaken cleaning compound shall be poured into each of two
chemically clean 250-ml pressure-resistant clear glass bottles which shall be approximately 9.5
inches (24.1 cm) in height and 2.5 inches (6.4 cm) in outside diameter. One bottle shall be
capped and stored in the dark for at least six days at room temperature. A strip of steel 6 by 0.5
by 0.02 inches (15.2 x 1.3 x 0.05 cm) conforming to MIL–S–7952 shall be polished to remove
surface contamination and then cleaned by boiling for one minute in chemically pure isopropyl
alcohol and one minute in mineral spirits. The steel strip shall be placed in the other test bottle
and the bottle shall be capped. The capped bottle containing the steel strip shall be thoroughly
shaken for one minute.

C. Procedure
The capped bottle containing the steel strip shall be placed in a water bath and heated at a uniform
rate to a temperature of 140° ± 4°F (60° ± 2°C) over a period of five hours. It shall be held at this
temperature for three hours. No heat shall be applied to the bath overnight. The above heating
procedure shall be repeated each day for five days. (This test need not necessarily be attended if an
interval time is used to regulate the temperature automatically. The test may be started on a
Wednesday, Thursday or Friday and still have the pressure bottle removed on a normal workday.) On
the morning of the sixth day, the bottle shall be removed from the bath, uncapped, examined for
separation and the steel strip carefully withdrawn from the cleaning compound. Separation into layers
shall be cause for rejection. The portion of the steel strip, which had been immersed in the compound,
shall be examined for evidence of pitting, corrosion and uneven darkening. The open bottle shall be
capped and the two bottles shall be thoroughly shaken for one minute, then allowed to remain
undisturbed for one hour at room temperature and then examined. Any marked change in the color
and uniformity of the aged sample shall be considered as showing unsatisfactory stability properties.

Table A1. Chemical Content of Washing Detergent

Total alkali metals 25 ppm max

Magnesium + calcium 5 ppm max

Vanadium 0.1 ppm max

Lead 0.1 ppm max

Tin + copper 10 ppm max

Sulfur 50 ppm max

Chlorine 40 ppm max

© 2013 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 25
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK111895 Rev E Released 8/15/2013 Page 26 of 28

GEK 111895E F-Class Gas Turbine Compressor Washing

V. CUSTOMER SUPPLIED NON-GE WATER WASH SKID

If a customer or AE provides the water wash skid, then the party providing the skid shall be responsible
for the proper function and operability of the water wash skid. The operation of the on-line and off-line
wash will be controlled from the plant Distributed Control System or Mark* VI Controller. The DCS or
Mark* VI Controller will provide a switching circuit only to start the pump (signal name L4WWX) and to
operate the off-line rinse recirculation valve solenoid (signal name L20WDET-1).

The primary GE requirements to be met by the customer include the following:

1. Provide the instrumentation, control wiring and interface with the GE turbine control panel.
2. The water wash solution must meet the Quality Specification of Table 1 and the detergent
concentrate must meet the requirements of Appendix 1.
3. Interface points from customer supplied water wash skid to GE purchaser connections shall meet the
flow, pressure, and temperature requirements defined in the Piping Schematic Diagram (MLI 0442).
4. The interface points from the customer supplied water wash skid to the GE Turbine Control Panel
shall be checked. It is the customer scope and responsibility to ensure the contact outputs from the
turbine control panel to the customer supplied water wash skid function.
5. During off-line water washing, the cycling of valve VA16–1, via solenoid driver 20TW–4, located
on the Piping Schematic Diagram (MLI 0442), shall be taken into account during the design of the
customer supplied water wash skid. The valve will open and close during the off-line water wash
and rinse cycles.
6. The customer is responsible for meeting other design requirements that include but are not limited to
the following list:
a. Weather and freeze protection
b. Seismic and structural loads
c. Lifting lugs
d. Foundation
e. Acoustic limits
f. Tank size
g. Tank heater
h. Tank vent, overflow line and connection to plant drain system
i. Power supply to pump motor
j. Internal temperature control for skid with enclosure
k. Skid instrumentation
l. Control and skid fault detection system
m. Junction box
n. Lighting and receptacles

*
Trademark of General Electric Company.
26 © 2013 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK111895 Rev E Released 8/15/2013 Page 27 of 28

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK111895 Rev E Released 8/15/2013 Page 28 of 28

F-Class Gas Turbine Compressor Washing

GEK 111895E

g GE EnergyGeneral Electric Company

www.ge-energy.com

28 © 2013 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

SHEETS 1 & 2 WERE
DELETED FOR
TRAINING PURPOSES.
2014
 GE Power Generation GENERAL ELECTRIC COMPANY

VENDOR SUPPLIED DRAWING

GE NOT TO REVISE. GE REVISION LEVEL IS AS SHOWN ON THIS APPLIQUE
THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER

THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE
THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE

MLI : _________
E025 ___
1 OF ___
1

281B5885

IDEAS ENGINEERED

PROPRIETARY. Neither this document nor its contents may be used or reproduced JORD ASIA PTY LTD Phone: +61 2 8425 1500
in any manner without the written authorization of JORD ASIA PTY. LTD. 38 Oxley Street Fax: +61 2 8425 1555
Unless otherwise noted all dimensions are in millimetres Crow Nest, NSW, Australia, 2065 E-Mail: [email protected]
 WATER WASH SKID DESCRIPTION

Extracted from GE Drawing 393A7610 / Aker Process Solutions drawing 5035-MA-001

E025 7FA/7FB/7EA/9FA/9FB Water Wash Skid Installation, Operation and Maintenance Manual
FOR TRAINING PURPOSES ONLY – GE ETT

** Refer to the original document for full details of installation, operation and
maintenance procedures and in particular - safety precautions.**

General Overview
The Water Wash Skid is a packaged fluid system. The Water Wash unit is operated in
certain cleaning modes of the gas turbine. When water or detergent solution is required at
the turbine, the operator starts the water pump and by proper valve manipulation on the
water wash unit, either plain water or water/detergent solution is pumped from the water
wash unit to the turbine.

Nozzles on the turbine govern the water flow rates. The Water Wash centrifugal pump
reacts on its curve to satisfy the nozzles employed. The detergent flow rates into the water
stream are governed by “valving” the detergent line through the venturi. The turbine
nozzles then govern the detergent/water solution flow rates in the same manner as the
water flow rates.

Water Wash System Equipment Description

- See General Arrangement and Piping Drawings for details.

The Water Wash Skid is comprised of the following major components:

• Water Tank
• Detergent Tank
• Skid Enclosure with removable roof
• Single Stage Centrifugal Pump
• Enclosure Ventilation Fan
• Compartment Space Heater (optional)
• Water Heaters
• Motor Control Cabinet
• Venturi Eductor
• Y-Strainer
• Pressure, Temperature and Flow Indicators

Water Wash Skid Description Page 1 of 8

 • Pressure, Level and Flow Switches, Thermocouples
• Ball / Ball Float / Globe / Needle & Check Valves
• Air Conditioner (optional)

Tanks

Water Tank is equipped with ball float valve assembly to close inlet line when water level is
full. Tank is also equipped with temperature indicator, sight glass, level switch,
thermocouple element.

Detergent Tank is equipped with ball float valve assembly to close discharge line when
detergent level is low. It is also equipped with sight glass to monitor detergent level in tank.

Pump Assembly

Pump utilized is a horizontal single stage centrifugal pump design and used to circulate
water through the system.

Venturi Eductor

Eductor is used to mix water and detergent with a correct ratio.

Y-Strainer including Filter Element

An 80-mesh stainless steel perforated metal screen installed in stainless steel Y-strainer is
used to filter water prior to entering the pump.

Valves

Main Tank Discharge Isolation Valve (normally open)

The isolation valve is stainless steel manual ball valve, used to shut-off water supply from
water tank to the system.

Recirculation Isolation Valve (normally open)

The isolation valve is stainless steel manual ball valve located after pump discharge.

Outlet Isolation Valve (normally open)

The isolation valve is stainless steel manual ball valve located on main discharge line prior
to customer connection WW20. Valve is used to isolate water supply to turbine.

Water Wash Skid Description Page 2 of 8

Y-Strainer Drain Valve (normally closed)
Valve is used to drain water in piping system to allow for strainer basket removal.

Water Tank Drain Valve (normally closed)

Valve is used to drain water in tank.

Detergent Line Globe Valve (normally open)

Globe valve is used to throttle the detergent flow to the eductor.

Main Tank and Detergent Tank Discharge Check Valves

Check valves are located on tank discharge lines and are designed to prevent
water/detergent flow returning back along the discharge line.

Water Tank Ball Float Valve

Ball float valve is used to close water tank fill line when water level is full.

Detergent Tank Ball Float Valve

Ball float valve is used to close detergent tank discharge line when detergent level is low.

Solenoid Valve (20WDET) (optional)

Solenoid valve is a 2-way valve used to recalculate water back to tank. Opens/close upon
signal from turbine control panel (MK VI). Solenoid valve is used on F/FA/FB and H water
wash units during pulse mode wash.

Solenoid Shut-Off Isolation Valve (optional)

Manual valve is used in recirculation line upstream of solenoid valve (20WDET) to prevent
detergent mixture entering the tank during off-line wash.

Motor Control Cabinet

One Motor Control cabinet is utilized for interfacing with the Water Wash System. Cabinet
contains Stop/Start buttons for manual & automatic operations, PLC, space heater, high
temperature switch and main power isolation.

Operator Controls on Control Panel - JB323

Main Isolator Selector Switch

Isolates main power supply to electrical system control on water wash system.

Operation Selector Switch (43WK-2)

Selects control circuit to operate in automatic (“AUTO”), or manual (“MANUAL”) mode.

Pump Motor Isolator Selector Switch (88TW-1)

Turns the pump motor control off or on.

Water Wash Skid Description Page 3 of 8

Stop Push Button
Press to stop motor controls.

Manual Start Push Button

Press to start the motor controls in ‘manual’ mode

Operator Controls on JB10 Control Panel

Fault Reset Push Button

Pressed to reset the motor controls after trip condition occurs.

Lamp Operate Test Push Button

Pressed to check alarm lights on JB10 panel are operating.

Run On Light
Indicates the pump motor contactor is energized and the motor should be operating.

Low Inlet Pressure Alarm Light

Indicates that vacuum switch 63TW-2 has sensed a low inlet pressure.

Low Outlet Pressure Alarm Light

Indicates that pressure switch 63TW-1 has sensed a low pump discharge pressure.

Low Flow Alarm Light

Indicates that flow switch 80WW-1 has sensed a low flow on system.

Water Pump Overload Alarm Light

Indicates that thermal switch in motor windings has sensed a thermal overload condition.

Water Wash Pump Trip Alarm Light

Alarm light energizes when trip occurs

Compartment Heater Alarm Light

Alarm light energizes to indicate that compartment heater is not operating.

Compartment Low Temperature Alarm Light

Indicates low temperature in the skid sensed by temperature element 26VW-3.

Compartment High Temperature Alarm Light

Indicates high temperature in the skid sensed by temperature element 26VW-3.

Tank Heater Alarm Light

Alarm light energizes to indicate that water heater is not operating.

Water Wash Skid Description Page 4 of 8

Low Level Water Tank Alarm
Indicates that water level in tank is low.

Low Water Temperature

Indicates low temperature in water tank sensed by temperature element 26TW-4.

Water Tank Heater

Heats water in tank to the desired temperature and provides freeze protection.

Switches

Vacuum Switch (63TW-2)

Located between Y-strainer and pump inlet. Disconnects water pump from service on
excessive pump inlet vacuum and initiates alarm signal to turbine control system.

Pressure Switch (63TW-1)

Disconnects water pump from service on loss of supply pressure and initiates alarm signal
to turbine control system.

Level Switch (71TW-1)

Located on water tank. Disconnects the water pump and water tank immersion heaters
from service once the water tank level reached a level just above the water tank suction
pipe and immersion heaters. Initiates alarm signal to turbine control system.

Level Switch (71TW-2) (optional)

Located on the water tank. Light is activated on the control panel when the level of water
increases above the high level mark.

Flow Switch (80WW-1)

Located in system piping to monitor water flow. Disconnects the water pump from service
on loss of flow. Provides signal to turbine control system water flow exists.

Indicators

Overflow Indicator
Used to indicate tank overflow situation in the Water Tank.

Pressure Gauge
Pump outlet gauge is provided to enable operators to check the operating pressure of the
system.

Water Wash Skid Description Page 5 of 8

Ammeter
Used to indicate the motor current.

Temperature Element

Temperature Element for Water Tank (26TW-4)

Provides signal to process controller to regulate water tank immersion heaters to maintain
desired water temperature.

Temperature Element for Compartment (26VW-3)

Located on JB10 panel, senses ambient temperature in the water wash unit compartment
to provide signal for automatic on/off operation of the compartment ventilation fan and
compartment space heater.

Compartment Space Heater (optional)

An electric space heater is used in fully enclosed water wash unit to keep the internal
temperature of water wash unit at a minimum of 50°F (10°C) at a minimum ambient
temperature of -40°F (-40°C).

Air Conditioner (optional)

Air conditioner is used in a fully enclosed water wash unit to keep the internal temperature
of the water wash unit at a maximum of 77°F (25°C) at a maximum ambient temperature
of 104°F (40°C).

Operation of the Water Wash Skid

Water wash unit is provided with control circuits for “Automatic On-Line Wash”,
“Compartment Temperature Alarm” and “Water Tank Temperature Control”. Junction Box
Control Panel (JB-10) is provided to support communications with the gas turbine control
system. Logic function is accomplished by Programmable Logic Controller (PLC) which is
located in the electric control center.

There are two operation types for the water wash unit, automatic (on-line) and manual (off-
line). The operation of the skid is controlled from the central control room.

Automatic On-Line Wash

On-line mode is activated by selecting the Pump Motor Isolator Selector Switch 88TW-1 in
the “ON” position and Operation Selector Switch (43WK-2) on “AUTO” position. The system

Water Wash Skid Description Page 6 of 8

can now only be started from Turbine Control Panel (TCP). The motor contactor will not be
initiated until
• Power to the motor control circuit has been established, and
• Circuit from turbine control systems has been completed. The completed circuit
shall activate one relay (4WW). Relay 4WW shall control a contact in the motor
control center, and
• Motor starter selector switch (88TW-1) is in the “ON” position, and
• Water wash unit Operation Selector Switch (43WK-2) is in the “AUTO” position, and
• There is sufficient water level in the water tank.

The PLC will activate Lockout Timer, set at 20 seconds. The motor contactor will be
disconnected if
• There is inadequate water level in water tank sensed by Water Level Switch
(71TW-1), or
• The pump inlet vacuum is determined to be excessive in 20 seconds, as indicated
by pressure switch 63TW-2, or,
• The pump discharge pressure is not established in 20 seconds, as indicated by
pressure switch 63TW-1, or,
• The pump flow rate is not established in 20 seconds, as indicated by flow switch
80WW-1, or,
• Motor overload occurs.

The water wash unit interconnects with Mark VI computer by relay signals L4WWX,
L86WWX, L80WWN and L20WDET (optional). When the operator actuates water wash
master control switch, relay L4WWX instructs the MK VI computer to start the pump motor.

Relay L86WWX provides alarm / trip signal to the turbine control system. Pressure and flow
are given 20 seconds after pump start to initiate before relay L86WWX energizes showing
no alarm condition. Relay L86WWX shall lose power if:

• Pump discharge pressure is low, as indicated by pressure switch 63 TW-1, or

• Pump inlet pressure is low, as indicated by pressure switch 63TW-2, or
• Water tank level is low as indicated by level switch 71 TW-1, or
• Pump discharge flow rate is low indicated by flow switch 80WW-1, or
• Motor trips on thermal overload.

Relay L80WWN provides pump flow feedback signal to the turbine control system. Relay
L80WWN shall be energized if Operation Selector Switch 43WK-2 is in “Auto” position and
flow switch 83WW-1 indicates low flow condition.

Relay L20WDET connected to MK VI computer is used to operate solenoid valve (20WDET).

Manual Off-Line Wash

Water Wash Skid Description Page 7 of 8

Manual mode is activated by selecting the Operation Selector Switch 43WK-2 in the
“manual” position. This mode does not require any permissive relay (L80WWN) from the
Mark VI.

Recirculation line ball valve needs to be closed to prevent detergent entering main water
tank.

The system will trip if

• Pump discharge pressure is low, as indicated by pressure switch 63TW-1, or

• Pump inlet pressure is low, as indicated by pressure switch 63TW-2, or
• Water tank level is low as indicated by level switch 71TW-1, or
• Pump discharge flow rate is low indicated by flow switch 80WW-1, or
• Motor trips on thermal overload.

Pump will continue to run until stopped by the stop button on the panel or one of the fault
conditions described above occur.

Refer to GE Gas Turbine Manual for additional information and details

concerning the on-line and off-line water wash operations.

Water Wash Skid Description Page 8 of 8

Tab 19
 GEK 107415
Revised, June 2000

GE Power Systems
Gas Turbine

Starting System

I. GAS TURBINE STATIC START SYSTEM

A. System Function and Design Requirements

Power for startup of the gas turbine is provided by the static start system. The static start system provides
variable frequency voltage and current to the generator, in this way the generator serves as the starting
motor required for starting the gas turbine. The static start system consists of the following major com-
ponents:

1. Load Commutated Inverter (LCI)

2. Isolation Transformer

3. LCI Disconnect Switch

4. Slow Roll Motor (Turning Gear)

The turning gear provides the power necessary to breakaway and rotate the turbine prior to turbine start
and also to rotate the shafting after turbine shutdown to avoid deformation of its shafting.

The turning gear system consists of an induction motor, reduction gears, SSS clutch, electrical isolation,
and flexible coupling.

The turning gear will breakaway the turbine and slow roll at 5 to 7 rpm. In the event of power failure
the turning gear is equipped with a feature for manual turning of the rotor system.

Lubricating oil for the reduction gears is self–contained. Lubrication of the SSS clutch and output shaft
bearings requires continuous oil supply from the main lube oil system.

The SSS clutch is a positive tooth type overrunning clutch which is self-engaging in the breakaway or
turning mode and overruns whenever the turbine/generator shafting exceeds the turning gear drive
speed.

The insulated flexible coupling allows for angular and parallel misalignment as well as allowing for gen-
erator shaft axial expansion.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 2000 GENERAL ELECTRIC COMPANY
GEK 107415 Starting System

B. Operation

On a start signal, the lift oil pumps are started to lift the stationary rotor off of the bearing surfaces. The
bearing pressure lift system must be operating prior to energizing the turning gear. This significantly
reduces the amount of starting and break–away torque required for the machines and minimizes bearing
damage during startup. Breakaway of the rotor system is accomplished by energizing the turning gear
induction motor. A double reduction worm gear reducer is furnished with a hollow shaft in which the
SSS clutch is mounted. Automatic engagement of the SSS clutch provides direct power transmission
to the rotor system. The turning gear will rotate the rotor system to 5 to 7 rpm. As the static starter begins
the starting sequence and accelerates the rotor the SSS clutch will automatically disengage the turning
gear from the turbine rotor.

The static starter will begin operation in the “pulsed” mode, changing to the “load commutated” mode
as soon as possible. The static starter will supply the variable frequency stator (armature) current re-
quired by the generator to operate as a synchronous motor and drive the gas turbine. The static starter
will control the excitation system during static starting to regulate the field (rotor) current as required
to maintain the required flux and generator voltage. The static start system operates to accelerate the tur-
bine to 25 to 30 percent of rated speed to purge the system for several minutes. At the end of the purge
period the LCI removes power from the generator allowing the unit to coast down to approximately 15%
speed and the turbine is fired and then accelerated to a self sustaining speed of about 90%. The static
starter currents will be reduced as required until the starting means is no longer required. After self sus-
taining speed is accomplished the control system will load and synchronize the gas turbine generator.
Operation of the neutral ground and stator disconnect switches is automatically controlled during the
starting process.

Upon turbine shutdown, as the turbine decelerates to below turning gear speed (5 to 7 rpm), the SSS
clutch engages if the turning motor is energized to provide slow roll rotor cooldown. This cooldown con-
tinues until proper gas turbine wheelspace temperatures drop to ambient.

In the event of a power outage when rotor turning is required, a manual turning assembly is provided
to turn the rotor. This manual turning feature can also be used for borescope inspection of the gas turbine.

The turning gear system is sized to provide breakaway of the shafting system with the bearing pressure
lift system operating on both the gas turbine and generator for manual and motor turning of the rotor
train.

C. Operating Precautions

* * * WARNING * * *

This equipment contains a potential hazard of electric shock or

burn. Only personnel who are adequately trained and thoroughly
familiar with the equipment and the instructions should install, op-
erate, or maintain this equipment.
Isolation of test equipment from the equipment under test presents
potential electrical hazards. If the test equipment cannot be
grounded to the equipment under test, the test equipment’s case
must be shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved ground-
ing practices and procedures must be strictly followed.

2
GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354
GE Energy GEI-100792B

LS2100e Static Starter Control

Product Description
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency
to be met during installation, operation, and maintenance. The information is supplied for informational purposes only, and
GE makes no warranty as to the accuracy of the information included herein. Changes, modifications, and/or improvements to
equipment and specifications are made periodically and these changes may or may not be reflected herein. It is understood
that GE may make changes, modifications, or improvements to the equipment referenced herein or to the document itself at
any time. This document is intended for trained personnel familiar with the GE products referenced herein.

GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this document
does not provide any license whatsoever to any of these patents.

This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to
assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document
shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of
GE Energy.

GE provides the following document and the information included therein as is and without warranty of any kind, expressed or
implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.

If further assistance or technical information is desired, contact the nearest GE Sales or Service Office, or an authorized
GE Sales Representative.

© 2011-2012 General Electric Company, USA. All rights reserved.

Revised: 2012-10-18
Issued: 2011-03-21

* Trademark of General Electric Company

ANSI is a registered trademark of American National Standards Institute.
ASME is a trademark of The American Society of Mechanical Engineers Corporation.
CE is a trademark of the European Union.
IEC is a trademark of Commission Electrotechnique Internationale Non-profit International Association.
IEEE is a trademark of Institute of Electrical and Electronic Engineers.
NEMA is a registered trademark of the National Electrical Manufacturers Association.
UL is a trademark of Underwriters Laboratories, Inc.
Windows is a registered trademark of Microsoft Corporation.

GE Proprietary and Internal (Class II)

Contents
Overview ....................................................................................................................................................... 3
Acronyms and Abbreviations ............................................................................................................................. 5
Related Documents .......................................................................................................................................... 6
System Architecture ......................................................................................................................................... 7
Cabinet Enclosure ..................................................................................................................................... 8
Control Cabinet ........................................................................................................................................ 9
Cooling System Cabinet ............................................................................................................................. 10
Power Conversion Cabinets......................................................................................................................... 11
Power Converter.............................................................................................................................................. 13
Input Power ............................................................................................................................................. 13
Output Power ........................................................................................................................................... 14
Liquid Cooling System............................................................................................................................... 14
Control Hardware ............................................................................................................................................ 15
Operator Interface ..................................................................................................................................... 17
Protection ................................................................................................................................................ 18
Diagnostic Alarms..................................................................................................................................... 19
Self-test................................................................................................................................................... 19
Software Configuration ..................................................................................................................................... 20
Communications ....................................................................................................................................... 20
Applications ................................................................................................................................................... 21
Gas Turbine Startup Sequence ..................................................................................................................... 21
Torque Speed Curves ................................................................................................................................. 22
Generator Voltage versus Speed Curve .......................................................................................................... 23
System Configurations ...................................................................................................................................... 24
One Starter for One Turbine ........................................................................................................................ 24
One Starter for Multiple Turbines ................................................................................................................. 25
Two Starters for Multiple Turbines ............................................................................................................... 26
Factory Testing and Quality Assurance................................................................................................................. 30
Bridge Tests ............................................................................................................................................. 30
Final Assembly Tests ................................................................................................................................. 30
DFE Assembly Tests.................................................................................................................................. 30
Customer Witness Tests.............................................................................................................................. 31
Technical Specifications .................................................................................................................................... 34

2 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
Overview
The LS2100e Static Starter control is an adjustable speed ac drive system specifically
designed to start a gas turbine generator set. By operating the generator as a synchronous
motor, the static starter accelerates the turbine set according to a specific speed profile
that provides optimum starting conditions for the gas turbine. The LS2100e control
eliminates the need for separate starting hardware, such as an electric motor or diesel
engine, torque converters, and associated auxiliary equipment, thus opening up critical
space around the turbine base.

The LS2100e control contains a digital control that interfaces seamlessly with various
GE turbine and excitation controls, including the Human-machine Interface (HMI) and
Historian products. These devices communicate with each other over an Ethernet-based
data highway to form a fully integrated control system. The ToolboxST* application is
used to configure the LS2100e control which is the same application used to configure the
gas turbine and excitation controls.

The LS2100e control power converter is available in two power ratings: 8.5 MVA and
14 MVA. Both systems are designed to provide an optimal match to the starting power
requirements for both GE frame 7 and frame 9 gas turbine generator sets, respectively.

8.5 MVA LS2100e Static Starter Control

GEI-100792B Product Description 3

GE Proprietary and Internal (Class II)
 14 MVA LS2100e Static Starter Control

In addition to the lineup shown, the LS2100e controls are also available as a separate
Digital Front End (DFE) controls upgrade for retrofitting existing static starter
installations. In addition, the LS2100e controls and cooling system cabinets are available
with separation from the power conversion cabinets to facilitate a barrier or wall for
control room installations. Please contact your GE sales representative for more details.

4 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
Acronyms and Abbreviations
EGD Ethernet Global Data
FCSA Current Sensor Interface
FGPA Field Gate Pulse Amplifier
FHVA High Voltage Gate Interface
FHVB High Voltage Bridge Interface
HMI Human-machine Interface
HSLA High-speed Serial Link Interface
I/O Input and output
LAN Local area network
LCI Load Commutated Inverter
LED Light-emitting diode
LSTB LS2100e Static Starter I/O Terminal Board
LSGI LS2100e Static Starter Gating Interface
NATO Voltage Feedback Scaling
SCR Silicon-controlled rectifier
UCSB Universal Controller Stand-alone Version B
UDH Unit Data Highway
XOVR Crossover application

GEI-100792B Product Description 5

GE Proprietary and Internal (Class II)
Related Documents
For further information on the LS2100e Static Starter control product, refer to the
following documents:

• GEH-6708, ToolboxST User Guide for LS2100e Static Starter Control

• GEH-6797, LS2100e Static Starter Control Installation and Startup Guide
• GEH-6798, LS2100e Static Starter Control User Guide
• GEH-6799, LS2100e Static Starter Control Maintenance and Troubleshooting Guide
• GEI-100222, LS2100e Static Starter Control Current Sensor Interface Board
DS200FCSAG1A
• GEI-100223, LS2100e Static Starter Control Gate Pulse Amplifier Board DS200FGPA
• GEI-100224, LS2100e Static Starter Control High Voltage Gate Interface Board
DS200FHVAG1A
• GEI-100225, LS2100e Static Starter Control Voltage Feedback Scaling Board
DS200NATOG1A
• GEI-100256, Receiving, Handling, and Storage of GE Drive and Exciter Equipment
• GEI-100530, LS2100e Static Starter Control High Voltage Bridge Interface Board for
Gas Turbines IS200FHVBG1
• GEI-100665, Mark VIe Controllers UCCx and UCSx Instruction Guide
• GEI-100780, LS2100e Static Starter Control I/O Terminal Board (LSTB) Instruction
Guide
• GEI-100781, LS2100e Static Starter Control Gating Interface (LSGI) Board
Instruction Guide
• GEI-100782, High-speed Serial Link Interface (HSLA) Board Instruction Guide
• GEI-100787, EX2100e Excitation and LS2100e Static Starter Control Systems
Touchscreen Local Operator Interface Instruction Guide

6 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
System Architecture
The LS2100e control system architecture supports Ethernet local area network (LAN)
Unit Data Highway (UDH) communication. The following figure displays the power
source or grid, source switchgear (52SS), load switchgear (89SS), control module, and
Power Conversion Module (PCM), as well as interfaces to the HMI, exciter, and Mark*
VIe Turbine Control Panel (TCP).

LS2100e Control Simplified One-line Diagram

Power magnetics in the LS2100e control provide isolation, voltage transformation, and
impedance, including:

• Isolation transformer – feeds 3-phase ac input power to the LS2100e control power
converters with isolation from the ac system bus, and provides the correct voltage and
phasing to the static converters.
• Dc link reactor – an air core inductor that provides inductance to smooth the current
delivered by the static power converters.

Note Optional ac output reactors are also available.

GEI-100792B Product Description 7

GE Proprietary and Internal (Class II)
 The LS2100e control uses various circuit breakers and motor operated disconnect switches
to make the appropriate power connections required for operation. These are supplied
separately from the LS2100e control and include: 52SS, 52G, 89SS, and 89ND.

The 52SS circuit breaker is used to connect the primary side of the LS2100e control
isolation transformer to the system auxiliary bus. Depending on the application, either the
LS2100e control or the customer Distributed Control System (DCS) controls the 52SS
breaker. It must be closed during startup and may be left closed (optional) after startup.
The 89SS is a motor operated disconnect switch used to connect the static starter load
inverter output bus to the generator stator. The turbine control system controls this switch.
The 89SS switch must be closed during startup and opened after startup. The 52G is
an optional circuit breaker used to connect the generator stator to the system bus. The
turbine control system controls this breaker and it must be open during startup. The 89ND
disconnect switch is used to disconnect the neutral grounding device from the generator
during static start mode.

Cabinet Enclosure
The LS2100e control is supplied in a factory assembled and tested freestanding enclosure.
The isolation transformer, dc link inductor, and heat exchanger are supplied separately.

Cabinet Enclosure Specifications

• Mounting:
− Indoor
− NEMA®Type 1 ventilated enclosure
• Frame:
− Rigid steel frame
− Enveloped by sheet steel
− Minimum 12-gauge thickness
• Paint: ANSI® -70 light gray

For additional enclosure specifications, including dimensions and

weight, refer to the section, Technical Specifications

LS2100e Cabinet Enclosure

8 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Control Cabinet
The LS2100e control cabinet has two front access hinged doors that are held in the closed
position with four latch screws that require a tool for opening and a single point handle.
The handle is equipped with a padlock hasp for locking the cover in the closed position.
The control cabinet contains the following components:

• Control power circuit breaker

• Control power transformer and power supplies
• Universal Controller Stand-alone Version B (UCSB)
• Panel mounted relays
• LS2100e Static Starter I/O Terminal Board (LSTB)
• LS2100e Static Starter Gating Interface (LSGI) board
• Crossover (XOVR) power input and power supply
• Customer terminal blocks

LS2100e Crossover Control Cabinet (Inside)

GEI-100792B Product Description 9

GE Proprietary and Internal (Class II)
 Cooling System Cabinet
The cooling system cabinet is located behind the control cabinet and accessed from the
rear of the lineup. The cabinet has two hinged doors that require a tool for opening and are
equipped with a padlock hasp for locking the cover in the closed position. Located inside
the cooling system cabinet are the following:

• Reservoir
• Deionizer
• Filter
• Pumps (two)
• Temperature regulating valve
• Pressure switch and pressure gauge
• Resistivity/temperature sensor
• Level switches

Cooling System Cabinet

10 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Power Conversion Cabinets
The power conversion cabinets have hinged covers that require a tool for opening and
are equipped with a padlock hasp for locking the cover in the closed position. Panels
bolted on the cabinet cover the rear sections, requiring access only for high voltage bus
connections. Located inside the power conversion cabinets are the following:

• Source thyristor converters

• Source ac line filters
• Load thyristor converter
• Load ac line filter
• Gate Pulse Amplifier (FGPA) boards
• High Voltage Gate Interface (FHVA) boards
• High Voltage Bridge Interface (FHVB) boards
• Voltage Feedback Scaling (NATO) board
• Current Sensor Interface (FCSA) boards

8.5 MVA Power Conversion Cabinet

GEI-100792B Product Description 11

GE Proprietary and Internal (Class II)
 14 MVA Power Conversion Cabinet

12 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
Power Converter
The LS2100e control power converter consists of two series connected, line-commutated,
phase-controlled thyristor source converters that feed a load-commutated thyristor load
inverter through a dc link reactor.

8.5 MVA Power Circuit One-line Diagram

The source converter gating is digitally controlled to produce the required current through
the dc link and the load. The dc link reactor is sized to keep the dc link current continuous
over the system’s operating range. The load inverter gating is digitally controlled to
produce a variable frequency ac output current to the generator stator terminals.

Input Power
The main input power to the source converters is provided through the LS2100e control
isolation transformer. The isolation transformer is designed for rectifier service and is
either oil filled or a dry type (as required by the customer).

The isolation transformer is The transformer contains two sets of 3-phase secondary windings, each rated at 2080 V ac
supplied separately from the (half the rated load inverter voltage). One source converter is fed from a delta-connected
LS2100e control. transformer secondary. The other source converter is fed from a wye-connected
transformer secondary. This arrangement phase-shifts one converter's 3-phase ac input
voltages by 30º compared to the other converter's 3-phase ac input voltages. This
configuration results in elimination of nearly half the harmonic currents generated by the
drive, most notably the 5th and 7th harmonics.

Note Consequently, the harmonic distortion imposed on the power system is reduced
more than half of what is produced by a conventional 6-pulse unit.

GEI-100792B Product Description 13

GE Proprietary and Internal (Class II)
 Output Power
Due to the high fault current capacity of the generator, the LS2100e control load inverter
output is connected to the starting bus through current limiting fuses. These fuses are
required to protect the power converter and interconnecting cables in the event of an
inverter fault during the starting operation.

An ac reactor is sometimes connected between the inverter and the current limiting
fuses to increase the commutating reactance for proper operation of the inverter. The ac
reactors are used when the phase-to-ground capacitance on the ac or dc buses exceeds
0.125 mfd. The output starting bus is connected to the generator stator by the motor
operated disconnect switch (89SS). The switch is rated based on generator terminal
voltage and LS2100e control full load current. The switch is electrically interlocked with
the generator main breaker (52G) to prevent operation of the switch when the generator
is connected to the system bus.

Liquid Cooling System

The LS2100e control power converter uses a liquid cooling system to transfer heat from
heat producing devices, such as silicon-controlled rectifiers (SCR) and high wattage
resistors, to a remote heat exchanger. The cooling system is a closed-loop system with
a covered reservoir for makeup coolant. Coolant circulates from the pump discharge to
the remote heat exchanger, to the power conversion bridges, and returns to the pump. A
portion of the coolant is bypassed to a deionizer system to maintain the coolant resistivity.

Cooling System Flow Diagram

Although both propylene and The coolant is a water/glycol mixture that prevents freezing from lower outside ambient
ethylene glycol are approved temperatures. The system should initially be charged with a mixture of distilled,
for use, propylene glycol is de-mineralized or de-ionized water and pure glycol. Makeup coolant must be a similar
preferred because of higher mixture to maintain the desired freeze protection.
electrical resistance, longer
deionizer life, and non-toxicity.

14 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Redundant pumps circulate the coolant. The pressure switch and interlocking pump motor
starters provide automatic transfer to the backup pump in the event of coolant pressure
loss. Isolation valves allow the pumps to be changed online without draining the system.

A remote mounted liquid-to-liquid heat exchanger is used to remove heat from the
closed-loop system. A remote mounted liquid-to-air heat exchanger can also be supplied.
The liquid-to-air heat exchanger includes redundant cooling blowers.

A coolant temperature switch and interlocking blower motor starters provide automatic
transfer to the backup blower. A temperature-regulating valve prevents the coolant
temperature from falling below a minimum of 27°C (80 °F) by allowing some of the
coolant to bypass the heat exchanger.

Control Hardware
The UCSB controller contains all control and protection features for the LS2100e control.
It interfaces to the control circuit boards through a high-speed serial point-to-point
communication link (HSSL). The LSGI interfaces to the circuit boards in the power
conversion cabinet to provide gating signals for the thyristors and collect voltage, current,
and status feedback.
LS2100e Control Circuit Boards
Board Location Description
UCSB Control cabinet Digital signal processor control, network interface, and customizable
application control board
LSGI Control cabinet Gating interface board
LSTB Control cabinet I/O interface board
HSLA Control cabinet High-speed serial link interface board
FGPA Power conversion cabinet Gate pulse amplifier board
FHVA Power conversion cabinet High voltage gate interface board
FHVB Power conversion cabinet High voltage gate interface board
NATO Power conversion cabinet Voltage feedback board
FCSA Power conversion cabinet Current feedback board

GEI-100792B Product Description 15

GE Proprietary and Internal (Class II)
 8.5 MVA Static Starter Control One-line Diagram

16 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Operator Interface
For touchscreen details and The operator interface is available in two forms: web or optional touchscreen. Both
operating guidelines, refer interfaces contain identical screens and functionality.
to GEI-100787, EX2100e
Excitation and LS2100e Web operator interface - standard on all products and can be initiated through any
Static Starter Control Systems LS2100e control UDH connection.
Touchscreen Local Operator
Touchscreen operator interface - an optional device that can be mounted on the control
Interface Instruction Guide.
cabinet door.

The operator interface provides:

• Status screens
• Alarm reset
• Pump and blower selection

Main Screen and Cooling Status Screen

The operator interface screens include:

• Main screen - the default screen displayed during connection to the LS2100e control.
It uses variable displays and animated bar graphs with associated text to display
performance data such as speed and output amps.
• Setup screen - provides configuration options and password protection.
• Cooling status - displays cooling system information and enables the user to change
pump and blowers.
• LSTB I/O status - displays the LSTB contact input and output status.
• LSGI status - displays the LSGI analog input and output values and contact I/O status.

GEI-100792B Product Description 17

GE Proprietary and Internal (Class II)
 Protection
The LS2100e control includes internal protection that conforms to the Integrated Control
System (ICS) protection philosophy of relying on the emergency external system
protection only when there is a failure of the primary internal protection. This allows
the static starter control to attempt corrective action on partial faults resulting in more
graceful handling of error conditions, such as initiating a controlled shutdown on loss
of feedback rather than letting external over-current emergency protection activate.
Protection includes:

• Instantaneous overcurrent
• Bridge differential current
• Generator overvoltage
• Source bridge undervoltage, overvoltage
• Ground fault
• Bridge coolant over temperature, low resistivity, low pressure, low/high level
• Shorted thyristor
• No generator field at start

18 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Diagnostic Alarms
Refer to GEI-100620, The LS2100e control diagnostics continually test for abnormal conditions. When an alarm
WorkstationST Alarm Viewer is detected, the system displays a message in the WorkstationST* Alarm Viewer. Summary
Instruction Guide. diagnostics are provided to the HMI alarm screens through the unit data highway (UDH).
All diagnostic alarms are time stamped with the time obtained from the Ethernet UDH. A
diagnostic alarm initiates one of the following:

Refer to GEH-6708, ToolboxST • Alarms require attention but do not shut down the LS2100e control. If the alarm
User Guide for LS2100e doesn’t clear itself, reset the LS2100e control to clear the alarm.
Static Starter Control, Chapter • Trips shut down the LS2100e control or prevent it from starting. The LS2100e
6 Working Online With an control should not be restarted until the condition causing the trip has been corrected.
LS2100e Component, the
section, Diagnostics Views.
Self-test
The LS2100e control is designed with self-test features that isolate problems with a
replaceable unit. Internal diagnostics monitor control board and processor operation
without requiring generator operation. HSSL cables are monitored for continuity. The
LS2100e control performs the following:

• UCSB controller diagnostic self-tests

• HSSL communication verification
• System and board power supplies verification
• Control board (LSGI/LSTB) health status checks

All thyristors are individually monitored for proper conduction status. In static starters
with redundant thyristors, this allows safe operation of the LS2100e control to continue
with one shorted thyristor until maintenance is performed.

Note Only the 14 MVA system includes redundant thyristors.

Refer to GEH-6797, LS2100e Additionally, the LS2100e control is capable of running a crowbar test on the entire
Static Starter Control system, during which current is circulated through the bridges but bypasses the generator.
Installation and Startup Guide, This allows proof of starter readiness without requiring power on the generator.
Chapter 6 Initial Startup and
Commissioning, the section,
Current Feedbacks Test.

GEI-100792B Product Description 19

GE Proprietary and Internal (Class II)
Software Configuration
The LS2100e control is configured with the ToolboxST application. The ToolboxST
application is a Windows®-based software package that typically resides on the HMI and
communicates to the static starter through the Ethernet.

Tuning changes are Having a digital control system permits fast field tune-up by allowing regulator gains
seldom necessary during and time constants to be altered by changing a parameter in non-volatile memory. The
commissioning. factory settings are specific to the site application. Control tune-up constants that can
be changed include:

• Current regulator
• Speed regulator
• Flux regulator
• System protection
• Scaling factors
• Data logging list

Communications
The LS2100e control supports Ethernet LAN communication to the following:

• GE Mark VIe product line, including turbine controls, ICS controls, static excitation
controls, starter crossover panels, and HMI, using the Ethernet global data (EGD)
protocol.
• ToolboxST application
• GE On-site Support* for remote monitoring and diagnostics

20 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
Applications
During startup, the turbine control supplies the run command and speed setpoint signals to
the LS2100e control. The static starter operates the power converter in closed-loop mode
to deliver variable frequency current to the generator stator. By controlling generator field
voltage and stator current, the static starter is able to adjust the torque produced by the
generator and control the acceleration and speed of the turbine generator set.

Note During startup, the field voltage setpoint is provided by the LS2100e control to
regulate the generator stator terminal voltage.

Gas Turbine Startup Sequence

Initially, the gas turbine generator set is spinning at turning gear speed 3-6 rpm. At
startup, the LS2100e control connects to the generator stator and assumes control of the
field voltage reference. The LS2100e control then accelerates the turbine to the purge
speed setpoint (typically 25% of synchronous speed). The turbine is held at purge speed
for approximately six minutes.

Following the purge, the LS2100e control output is turned off and the turbine is allowed
to coast down to the firing speed of 15%. The output is turned on again and the turbine
is fired. The turbine is briefly held at constant speed to allow for warming. Once the
warming period is completed, the static starter accelerates the turbine to its self-sustaining
speed. The LS2100e control is turned off and disconnected from the generator.

Typical Gas Turbine Startup Sequence

GEI-100792B Product Description 21

GE Proprietary and Internal (Class II)
 Torque Speed Curves
A typical gas turbine torque speed curve displays the turbine load torque (unfired torque
and fired torque) and the generator output torque (motor torque). The acceleration torque
is determined by the difference between the generator output torque and the turbine load
torque. The acceleration torque and the inertia of the shaft determine the acceleration rate.
As the accelerating torque becomes larger the turbine is accelerated faster. The LS2100e
control adjusts the generator output torque to have the turbine follow the startup sequence.

Torque Speed Curves

The turbine is accelerated in an unfired mode up to approximately 25% speed and fired
at 15% speed. The period between these two points is the wobulating purge and coast
down. At 90% speed, the torque produced by the turbine is sufficient to accelerate to
top speed and the static starter is disabled.

22 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Generator Voltage versus Speed Curve
The following figure displays a typical generator starting voltage profile. During startup
the generator field current is controlled so that the generator stator flux does not exceed
allowable limits. The LS2100e control output voltage increases linearly from 0 to its
rated value of 4160 V ac as the speed increases from near 0 to 30 Hz (for 7F turbine
applications), providing constant V/Hz (flux) on the generator. Above 30 Hz, the static
starter output voltage is held constant and V/Hz falls off inversely with speed.

Generator Voltage/Flux versus Speed Curves

GEI-100792B Product Description 23

GE Proprietary and Internal (Class II)
System Configurations
Several standard configurations The following sections illustrate the various starting system configurations that are
are described in this section available and define the benefits associated with each. The starter configuration label
but other configurations are convention is determined by the number of starters, 89MD, generators, 89SS, and 89TS
available. devices in the starting envelope. For example, a one starter on one generator system would
be labeled as a 10110 configuration. The LS2100e control starting system configuration
should be chosen to provide the best optimization of cost and starting availability.

Note Only one generator can be started at a time by any one static starter.

One Starter for One Turbine

There are no provisions for In this configuration, one static starter control is responsible for starting only one turbine
redundancy with this system. generator set. There is a single starting bus associated with the one static starter control.
The generator has an 89SS motor operated switch that is used to connect the generator
stator to the starting bus. This is the simplest system, both in terms of physical layout
and implementation.

One-on-one Configuration (10110)

24 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 One Starter for Multiple Turbines
In this starting system configuration, one static starter control is responsible for starting
two, three, or four turbine generator sets. There is a single starting bus associated with the
one static starter control. Each generator has an 89SS motor operated switch that is used
to connect the generator stator to the starting bus.

One-on-four Configuration (10440)

There are no provisions for This configuration is only slightly more complex than the one-on-one system and provides
redundancy. the economic benefit of sharing a single LS2100e control across multiple turbine generator
sets. The LS2100e control can start any one of the available turbines at any time.

Note The operator can select the turbine generator set that is to be started from the
graphic screen on the HMI.

GEI-100792B Product Description 25

GE Proprietary and Internal (Class II)
 Two Starters for Multiple Turbines
In this configuration, two static starter controls are responsible for starting two to eight
turbine generator sets. There are two starting buses, one associated with each LS2100e
control. Each static starter control has an 89MD motor operated switch that is used to
connect to the respective starting bus. Each generator has an 89SS motor operated switch
that is used to connect the generator stator to one of the two starting buses. An 89TS motor
operated switch is used to connect the two starting buses.

Two-on-four Configuration (22441)

The operator can select the This configuration provides redundancy using two static starter controls. When the 89MD
turbine generator set that is to and 89TS switches are configured appropriately, either LS2100e control can start any of
be started using the graphic the turbines. By closing the 89TS switch to connect the two starting buses, a static starter
screen on the HMI. control is able to start a turbine generator set connected to the other LS2100e control’s
starting bus. Additionally, by leaving the 89TS switch open to isolate the two starting
buses, both static starter controls can be used to simultaneously start two turbine generator
sets (provided the power system is capable of tandem starts). This allows generating
capacity to be brought online faster.

26 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 The two-tie switch starting system configuration, using two static starter controls, uses
three starting buses and two 89TS switches.

Two-on-three with Two Tie Switch Configuration (22332)

The operator can select the When the 89MD and 89TS switches are configured appropriately, either LS2100e control
turbine generator set that is to can start any of the turbines. One or both of the 89TS switches must be closed for an
be started using a graphical LS2100e control to be able to start a turbine generator set connected to one of the other
selection screen on the HMI. starting buses. Additionally, both LS2100e control’s can be used to simultaneously start
two turbine generator sets, provided the power system is capable of tandem starts. In this
case, one or both of the 89TS switches must be opened to isolate the two starting buses.

GEI-100792B Product Description 27

GE Proprietary and Internal (Class II)
 Crossover (XOVR) Configuration Component Maintenance
Note Consult your site-specific one-line diagram before attempting any maintenance
and simultaneous starting of additional units.

If maintenance is performed on components in a GTE of Gen1, it is not possible to use

LCI unit #1 to start any of the units (refer to the following diagram). However, by using
an 89TS switch, LCI unit #2 may still be used to start Gen 3 or Gen 4. On configurations
without 89TS-1 and 89TS-2, it is not possible to start any unit if a GTE is in a proper
LOTO status with the starting bus side of the 89SS grounded.

Sample XOVR Configuration

28 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Additional maintenance switches, 89MS, are required for isolation of the 89SS switches
while starting additional units on the bus, as well as safe maintenance work procedures
within the GTE. Optional 89MS switches are suitably sized for the application and can be
installed in series with the 89SS switch for each unit on the starting bus side.

Sample XOVR Configuration with Maintenance Switches

GEI-100792B Product Description 29

GE Proprietary and Internal (Class II)
Factory Testing and Quality Assurance
The following sections describe the quality assurance tests performed on new unit and
digital front-end (DFE) upgrade LS2100e Static Starter control equipment prior to
shipment.

Bridge Tests
Each LS2100e control bridge assembly is subjected to routine factory tests, including
but not restricted to the following:

• Complete electrical and mechanical inspection

• Hydrostatic coolant pressure
• Component impedance check to verify all SCRs and passive components
• Hipot and corona
• Gate pulse and cell firing
• Current and voltage feedback
• Thyristor voltage sharing
• Rated voltage operation
• High current, low voltage

Final Assembly Tests

Each static starter control lineup is subjected to routine factory tests, including but not
restricted to the following:

• Hydrostatic coolant pressure

• Cooling system
• Processor and I/O
• Fiber-optics
• Bridge current and voltage feedback

DFE Assembly Tests

Each DFE static starter control lineup is subjected to routine factory tests, including
but not restricted to the following:

• Processor
• Power distribution
• Resistivity meter
• Circuit board I/O
• Interposing relay I/O

30 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Customer Witness Tests
All equipment goes through extensive testing with appropriate reviews and sign-offs for
the tests previously mentioned. After that, the customer can select any of the following
options for a customer witness test.

Option A, New unit, or DFE allows the customer to examine the appearance and
workmanship of the equipment, then review the engineering and test paperwork. This is a
standard service for no additional charge.

Option B, New unit allows the customer to witness a demonstration of the hardware with
power on. This is an added-cost item to the customer.

Option B, DFE allows the customer to witness a demonstration of the control cabinet with
power applied. This is an added-cost item to the customer.

GEI-100792B Product Description 31

GE Proprietary and Internal (Class II)
 Option A, New unit, or DFE
There is no additional cost This normal production inspection, performed immediately prior to shipment, verifies
associated with this option. the mechanical integrity, conformance to special purchaser hardware requirements,
appearance, and design completeness of the enclosure. The purchaser can elect to
participate in this inspection at no charge. This inspection lasts approximately two hours
and includes the following:

• Inspection of appearance and mechanical integrity

• Review for completion
• Test instructions
• Test log
• Test defect record
• Check engineering log
• Inspection defect records
• Shortages
• Audit T check (labeling/nomenclature)
• As-shipped prints
• Purchaser special requirements

The customer usually inspects the hardware the day before the unit is sent to shipping.
The unit was completely tested and inspected prior to the customer’s inspection. The
customer can inspect the unit to ensure that its appearance meets expectation before being
shipped. Generally, the customer reviews the quality of workmanship; looking at paint,
wiring, crimping, and assembly.

The second part of this option is a review with the engineer. The customer can review
all paperwork relevant to the engineering and testing of the requisition. This includes
the elementary, I/O list, alarm list, layouts, outlines (does not apply to DFE), and test
sign-off sheets. This documentation provides the basis for certification that the customer's
hardware went through the proper engineering, verification, and testing processes.

The customer should advise GE Energy eight weeks prior to shipment of their intent to
visit the factory to inspect equipment. GE will inform the customer two weeks prior to the
inspection date so that the customer can make travel arrangements.

32 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Option B, New unit
There is an additional cost This customer witness option consists of the following:
associated with this customer
witness point. • Demonstration of static starter control assembled lineup in the final assembly test
area, with 460 V power applied
• Demonstration of the door-mounted coolant temperature/resistivity meter
• Demonstration of the optional door-mounted touchscreen, if provided
• Operation of the power bridge, showing SCR firing pulses
• Visual inspection (not including the final visual inspection as cleanup work is done
after leaving the test area)

Option B, if selected, should be included as part of the initial purchase order. If a customer
decides to purchase this option after the initial ordering drawing release, an amendment
to the purchase order will be required. If option B was not initially purchased, then
notification of a change order is required at least eight weeks prior to shipment of the
equipment. GE Energy will inform the customer two weeks prior to the test date so that
the customer can make travel arrangements.

Option B, DFE
There is an additional cost This customer witness option consists of the following:
associated with this customer
witness point. • Demonstration of the static starter DFE control assembled in the final assembly test
area, with 460 V power applied
• Demonstration of the door-mounted coolant temperature/resistivity meter
• Demonstration of the optional door-mounted touchscreen, if provided
• Visual inspection (not including the final visual inspection as cleanup work is done
after leaving the test area)

Option B, DFE, if selected, should be included as part of the initial purchase order. If a
customer decides to purchase this option after the initial ordering drawing release, an
amendment to the purchase order will be required. If option B, DFE was not initially
purchased, notification of a change order is required at least eight weeks prior to shipment
of the equipment. GE Energy will inform the customer two weeks prior to the test date so
the customer can make travel arrangements.

GEI-100792B Product Description 33

GE Proprietary and Internal (Class II)
Technical Specifications
Summary characteristics for the LS2100e control are listed in the following tables. Unit
specific ratings are provided on the equipment nameplate and supersede all information
herein.
General
Item Description
Rectifier cells SCR
Source rectifier 12-pulse
Load rectifier 6-pulse
Bridge construction Heatsink/SCR, dual cell stack
Cooling Liquid
SCR replacement Offline without opening water circuits
SCR average replacement time 4 hours

Power Input
Item Description
Supply voltage 2080 V ac each bridge, ±10%
Supply frequency 50 or 60 Hz, ±5%
Supply phases 3-phase, ±2% unbalance

Power Output
Item Description
Nominal output power 8.5 MVA or 14 MVA
Nominal output voltage 0 to 4160 V ac
Nominal output frequency 0 to 50 or 60 Hz

Control Power
Item Description
Power 7 kVA
Frequency 50 or 60 Hz, ±5%
Voltage
50 Hz 400/415 V ac, ±10%
60 Hz 480 V ac, ±10%

34 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
 Cabinet Enclosure
Item Description
Type NEMA-1 ventilated
Paint ANSI-70 light gray (standard)
Dimensions (Wx D x H)
8.5 MVA 2800 mm x 1400 mm x 2550 mm (110.2 x 55.1 x 100.4 in)
14 MVA 4400 mm x 1400 mm x 2550 mm (173.2 x 55.1 x 100.4 in)
Weights
8.5 MVA 2700 Kg (5900 lb)
14 MVA 4082 Kg (9000 lb)
Control cable access Entrance from top or bottom
Power cable access Entrance from bottom

Environmental
Item Description
Relative humidity 95%, non-condensing
Operating temperature 0 to 40°C (32 to 104 °F)
Storage temperature -25 to 70°C (-11 to 158 °F)
Ambient transient thermal change 5°C (9 °F) per minute
Altitude < 1005.84 m (3300 ft)
Vibration Per EN 50178
Seismic UBC Zone 4

Codes and Standards

Item Description
Safety UL™ 508C, UL347A
CSA™ C22.2, #14
Dc link reactor ANSI C57.12.01 for construction
NEMATR-27 for audible sound
Remote heat exchanger Zone 4, ASME™

CE™ Mark
Item Description
LVD EN 50178
Electromagnetic Compatibility
EN 55011 Radiated and conducted RF emissions 2007
EN61000-6-2 Generic immunity industrial environment 2005
EN61000-4-2 Electrostatic discharge immunity 2001
EN61000-4-3 Radiated RF immunity 2008
EN61000-4-4 Surge immunity 2005
EN61000-4-6 Conducted RF immunity 2007
EN61000-4-11 Voltage dips, interruptions, and variations 2004

GEI-100792B Product Description 35

GE Proprietary and Internal (Class II)
 Dc Link Reactor
Item Description
Type Dry-type, air core
Voltage class 5 kV
Winding conductors Aluminum
Insulation Class H
Basic Impulse Level (BIL) ratings
4160 V 30 kV

Isolation Transformer
Item Description
Type Silicon oil filled (Optional - dry-type cast coil or dry-type open coil)
Standard ANSI/IEEE™ or IEC™
Rating Depends on GT frame, from 3.25 to 8.75 MVA
Connection Delta/Delta-Wye, 12-pulse
Primary One primary, voltage depends on the site, from 4.16 to 11 kV
Secondary Two secondary each 2.08 kV
Cooling and class Mineral oil ONAN, Air AN
BIL As per the standards, ANSI/IEEE or IEC

Cooling System
Item Description
Type Liquid, closed-loop
Coolant Water/propylene glycol mixture
Coolant resistivity Deionizer system with replaceable cartridge
Heat exchanger Full capacity liquid-to-liquid (Optional - full capacity liquid-to-air with redundant
cooling blowers and autochangeover)
Circulation pump Full capacity redundant
Monitors Resistivity
Pressure
Temperature
Coolant level
Local interface Resistivity indicator
Temperature indicator
Pump selection, blower selection (optional)
Miscellaneous Translucent coolant storage reservoir
Temperature regulating valve

Control Functions
Item Description
Local interface Optional door-mounted touchscreen and display
Configuration ToolboxST application
Communication protocols EGD

36 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
Notes

37 LS2100e Static Starter Control

GE Proprietary and Internal (Class II)
GE Energy Controls Technology
1501 Roanoke Blvd.
Salem, VA 24153–6422 USA
1 540 387 7000 www.geenergy.com

GE Proprietary and Internal (Class II)

 GEH-6374A

g (Supersedes GEH-6374)

GE Industrial Systems

ä LCI Liquid Cooling System

Innovation Seriesä

These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met
during installation, operation, and maintenance. If further information is desired or if particular problems arise that are not covered
sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems.
This document contains proprietary information of General Electric Company, USA, and is furnished to its customer solely to assist
that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall not be
reproduced in whole or in part, nor shall its contents be disclosed to any third party without the written approval of GE Industrial
Systems.

Safety Symbol Legend Section Page

Introduction............................................................................................................. 2
Coolant Circulating System .................................................................................... 3
Coolant Temperature and Condensation Control............................................. 6
Datapanel and OC2000 Indications and Operation................................................. 7
Datapanel Data Displays.................................................................................. 7
Indicates a procedure, practice, Datapanel Control Selections........................................................................... 8
condition, or statement that, if OC2000 Control Selections ............................................................................. 8
not strictly observed, could Heat Exchanger Installation .................................................................................. 10
result in personal injury or Overview........................................................................................................ 10
death. Materials ........................................................................................................ 10
Cleaning......................................................................................................... 10
Flushing ......................................................................................................... 10
Stress Relief ................................................................................................... 10
Allowable Pressure Drop ............................................................................... 11
Heat Exchanger Elevation.............................................................................. 11
Drain-Back Provision..................................................................................... 11
General Mechanical Provisions ..................................................................... 12
Indicates a procedure or
condition that, if not strictly
Liquid-to-Air Heat Exchanger Option ........................................................... 12
observed, could result in Liquid-to-Liquid Exchanger Option .............................................................. 12
damage to or destruction of Coolant Mixture .................................................................................................... 13
equipment. Propylene Glycol Concentration.................................................................... 13
Maintaining Coolant Concentration............................................................... 14
Startup Procedure.................................................................................................. 14
Note Indicates an essential or
Routine Maintenance ............................................................................................ 16
important procedure, practice,
Maintaining the Liquid Cooling System ........................................................ 16
condition, or statement.
Removal and Replacement Procedures ................................................................. 17
Carbon Filter and Deionizer Cartridge Replacement..................................... 17
Filter Replacement (If Supplied).................................................................... 17
Strainer Cleaning ........................................................................................... 18
Coolant Pump Replacement........................................................................... 18
Long-Term Storage ............................................................................................... 20
Warranty Terms .................................................................................................... 20
Time Limitations and Warranty..................................................................... 21
How to Get Help ................................................................................................... 21

Innovation Series is a trademark of General Electric Company, USA

GEH-6374A Innovation Series LCI Liquid Cooling System • 1

Introduction
These instructions describe the liquid cooling system used in the Innovation Seriesä
Load Commutated Inverter (LCI) only (does not include Static Starter applications).
The drive uses a liquid cooling system to transfer heat from heat producing devices
(such as SCRs and high wattage resistors) to a heat exchanger.
The liquid cooling system is a closed-loop system with a covered reservoir for
makeup coolant (see Figures 1 and 2). Coolant circulates from the pump discharge,
to the heat exchanger, to the power conversion bridges, and returns to the pump. A
portion of the coolant bypasses to a deionizer system to maintain the coolant
resistivity.
The liquid cooling system has the following features:
• Self-venting, closed-loop cooling system using a water and propylene glycol
mixture
• Full-capacity coolant circulation pump
• Redundant circulation pumps with automatic changeover and isolation valves
for maintenance
• Full capacity heat exchanger, either remote liquid-to-liquid or liquid-to-air with
cooling blower and optional redundant heat exchanger blowers with automatic
changeover
• Purity alarm monitor with digital resistance and temperature display and
contacts for alarm and trip
• Translucent coolant storage reservoir with cover and contacts for overflow
alarm, low-level alarm and low-level trip
• Deionizer system with isolation valve for maintenance
• Differential pressure switch across bridge
• Temperature switches
• Drain valves
• Temperature-regulating valve

2 • Innovation Series LCI Liquid Cooling System GEH-6374A

Coolant Circulating System
Isolation valves allow the Redundant pumps circulate the coolant. The differential pressure switch and inter-
pumps to be changed online locking pump motor starters provide automatic transfer to the backup pump at
without draining the system. 7 pounds per square inch (psi). Normal differential pressure is 15 to 40 psi.
The coolant circulating system is self-venting. During normal operation, it does not
require air venting or purging. The outlet side of the power conversion bridge
contains a manual vent.
The storage reservoir is at atmospheric pressure and determines the inlet pressure to
the circulating pumps. Make sure that the pumps are not run dry. While charging the
system, cycle the pumps as the system fills.
The reservoir is low-density polyethylene with a screw cap. Keep the reservoir cov-
ered to prevent unnecessary contamination of the system and coolant evaporation or
spillage. Ventilation to the atmosphere is through a vent in the top of the reservoir.
The liquid-to-air heat exchanger option includes redundant cooling blowers. A
coolant temperature switch and interlocking blower motor starters provide automatic
transfer to the backup blower.
A liquid-to-liquid heat exchanger for remote mounting can be supplied as an option.
This option does not use cooling blowers.

The heat exchanger is usually mounted at the same elevation

as the drive. If the heat exchanger is mounted above the
drive, coolant draining back into the system from the heat
exchanger can overfill the reservoir if the pump is
shutdown. Place the reservoir vent at an elevation above the
highest point in the closed loop cooling system to prevent
spillage if the pump is shutdown.

GEH-6374A Innovation Series LCI Liquid Cooling System • 3

 Terminal
Board CLF2 High Level Alarm

Reservior Cap Vent

(fill here)

Coolant
Reservior

CLA Low Level Warning

CLF1 Low Level Alarm

Pump 1

Outlet

Filter
Pressure
Inlet
Gauge Inlet
Charcoal
Filter

Pump 2
Deionizer

Flow To/
From Bridge Temperature
Strainer
Limit Switch

Temperature
Regulating Valve

Figure 1. Liquid Cooling System for Innovation Series LCI

4 • Innovation Series LCI Liquid Cooling System GEH-6374A

 FILTER RESISTOR FILTER RESISTOR
3 PARALLEL PATHS 3 PARALLEL PATHS

VENT
MANIFOLD

LIQUID COOLED BUS LIQUID COOLED BUS

3 PARALLEL PATHS 3 PARALLEL PATHS

LIQUID COOLED HEAT SINK LIQUID COOLED HEAT SINK

15 PARALLEL PATHS 21 PARALLEL PATHS

NON-CONDUCTING
SILICONE RUBBER HOSE

MOLDED HOSE

Pump WIRE REINFORCED HOSE

Panel

LOAD BRIDGE SOURCE BRIDGE

Figure 2. LCI Bridge Line Up, Rear View, Cooling Diagram (12/6 version)

The reservoir levels are:

Full: 38 liters (10 gallons)
Low low level alarm: 5 liters (1.4 gallons)
Low level alarm: 19 liters (5 gallons)
High level alarm: 46 liters (12 gallons)
Insulating hoses are used between the grounded cooling manifolds and the heatsinks,
which are at drive line voltage potential. Insulating hoses are also used between
heatsinks that are at different potentials.
See Routine Maintenance The insulating system must be maintained. This requires using exact replacement
section, Table 2 for hoses having at least 100 megohm per inch of resistance as confirmed by a 1000 V
recommended spare parts. dc megger. Use exact replacement hose clamps.
Large diameter hose used to interconnect between panels and hose used in the pump
panel can be conducting (wire-reinforced) or fabric-reinforced EDPM or Neoprene.
Silicone rubber hose is also used in the pump panel.

GEH-6374A Innovation Series LCI Liquid Cooling System • 5

 Coolant Temperature and Condensation Control
A temperature-regulating valve within the pump panel controls the coolant
temperature within the bridge to a minimum of 65 °F (18 °C) while the pump is
running. The valve keeps the bridge temperature above the ambient dew point, which
prevents condensation from forming within the bridge. Above 95 °F (35 °C) the
temperature of the coolant being delivered by the heat exchanger limits the
maximum temperature in the bridge.
Temperature alarm and fault messages are given at the following temperatures:
Temperature alarm: 68 °C (155 °F)
Temperature fault: 77 °C (170 °F)
A valve that will not fully close could allow condensation to form resulting in arcing
faults in the bridge. A valve that will not fully open could cause the bridge to
overheat and trip on the over temperature fault. Under certain operating conditions it
is possible to determine if your temperature-regulating valve has failed. Refer to
Table 1 and Figure 3.

Note If the temperature-regulating valve fails, the manifold assembly, which the
valve is located in, must be replaced with an assembly containing a new valve. The
part number for this manifold is 173C9237ABG1.

Table 1. Failure Indications for Temperature-Regulating Valve

Coolant Temperature Coolant Temperature from Internal Bridge

from Heat Exchanger (Figure 3, section B)
(Figure 3, section A)
<65 °F 65 °F – 95 °F >95 °F
< 65 °F Failed Unknown Failed
< 95 °F Failed Unknown Failed
> 95 °F Failed Unknown Unknown

Regulating Valve

Heat Internal
Heat Exchanger Cooling Loop Power
Exchanger Cooling Loop Bridge

A B
(Monitored by Datapanel)

Figure 3. Coolant Circulation

6 • Innovation Series LCI Liquid Cooling System GEH-6374A

Datapanel and OC2000 Indications and Operation
Under normal conditions, the liquid cooling system operates without human
intervention. Cooling system status can be determined through the Datapanel™ user
interface and/or through a remote OC2000 cooling system display.

Note The blower references on the screens illustrated in Figure 4 and Figure 5
apply to the liquid-to-air heat exchanger option. A system that uses a liquid-to-liquid
heat exchanger has no blowers and BLWR references on the menus should be
ignored.

Datapanel Data Displays

Access the Datapanel's COOLANT menu from the top level menu by pressing the
F2 (PUMP) function key. The COOLANT menu resembles Figure 4. The
COOLANT menu displays cooling system conditions. The example in Figure 4
displays that the temperature, resistivity, pressure, and coolant level are within
design limits (OK). The fields are as follows:
TEMP displays the messages ALARM, when the temperature begins to rise above its
optimum level, and FAULT, if the temperature exceeds the design limits. If the
FAULT message displays, the LCI bridge shuts down.
RESIS refers to the electrical resistivity of the coolant. It can display one of three
messages: OK, ALARM, or FAULT. The deionizer, when properly operating, keeps
the conductivity of the cooling solution low, and its resistivity high. If the resistivity
falls below a preset value (the FAULT case), the software shuts down the LCI
bridge.
PRESS can be either OK or LOW.
LEVEL can display four different messages: OK, LOW ALARM, LOW FAULT, and
HIGH FAULT. It is controlled by three sensors in the reservoir (see Figure 2).

Figure 4. Datapanel Coolant System Menu

GEH-6374A Innovation Series LCI Liquid Cooling System • 7

 Datapanel Control Selections
Datapanel control selections are as follows:
ON/OFF displays the operating status of the system (either ON or OFF) in large type
on the left side of the screen. To turn pumps or blowers on and off, use the
ON/OFF/AUTO switches in the pump panel.
PUMP SLECT selects which of the two coolant circulation pumps runs (press the F2
key to select). The assigned pump (ONE or TWO) is listed in the PUMP LEAD
field. The control software automatically switches to the other pump if coolant
pressure drops. As long as the selected pump maintains the necessary pressure, the
RUN field is the same as the PUMP LEAD field.
If the selected LEAD pump fails to maintain pressure, the RUN field lists which
pump is actually running. Since this field is linked to sensors on the pumps, it
reflects the actual status. It can display three values: ONE, TWO, or NONE. The
NONE message is displayed if pumps ONE and TWO both fail, or if both pumps are
switched off in the pump panel.

Note It is good practice to alternate the lead pump (one or two) at regular intervals
to ensure that the bridge has reliable backup cooling capacity and to even the wear
on the pumps.

The blower references below apply to the liquid-to-air heat

exchanger option only (the second blower is optional). A
system that uses a liquid-to-liquid heat exchanger has no
blowers and the blower status messages in Figures 4 and 5
should be ignored.

BLOWR SLECT selects which of the two blowers for the liquid-to-air heat exchanger
is running (press the F3 key to select). The assigned blower (ONE or TWO) is listed
in the BLWR LEAD field. The control software automatically turns on both blowers
if the coolant temperature rises beyond design limits. Both blowers stay on until
coolant temperature is OK and F4 RESET key is pressed. As long as the selected
blower keeps the radiators cool, the RUN field is the same as the BLWR LEAD
field.
If the selected LEAD blower fails to maintain temperature within limits, the RUN
field shows that BOTH blowers are running. Since this field is linked to sensors on
the blowers, it reflects the actual status. It can display four states: ONE, TWO,
BOTH, or NONE. This last message is displayed.

Note It is good practice to alternate the pump on duty at regular intervals to ensure
that the bridge has reliable backup cooling capacity.

The RESET button also clears SRESET triggers the RESET sequence of actions (press the F4 key to select). If the
the low coolant alarm. low pressure (or high temperature) condition that caused the system to go to the
backup pump (or both blowers) has cleared, pressing this key places the lead pump
(or blower) into service again.
BACK closes the coolant system menu and returns to the top level menu (press the
F6 key to select).

OC2000 Control Selections

A remote OC2000 can be used for the PUMP and BLOWER select functions from
the Cooling System menu (see Figure 5). Additional coolant system information will
still be shown on the Datapanel display. OC2000 control selections are as follows:

8 • Innovation Series LCI Liquid Cooling System GEH-6374A

 PUMP SELECT selects which of the two coolant circulation pumps runs (press the
PUMP 1 SELECT or PUMP 2 SELECT key). The assigned pump (1 or 2) is
indicated by the PUMP 1 SELECT LED or PUMP 2 SELECT LED. The actual
running pump is indicated by the corresponding PUMP 1 RUN LED or PUMP 2
RUN LED. The control software automatically switches to the other pump if coolant
pressure drops or the selected pump shuts down.
The backup pump will continue to run until the condition that caused the system to
switch to the backup pump is cleared and the RESET key is pressed.

Note The selected pump will continue to run as long as it maintains the necessary
pressure. It is a good practice to alternate the lead pump (one or two) at regular
intervals to ensure that the bridge has reliable backup cooling capacity and to even
the wear on the pumps.

BLOWER SELECT selects which of the two blowers runs (press the BLOWER 1
SELECT or BLOWER 2 SELECT key). The assigned blower (1 or 2) is indicated by
the BLOWER 1 SELECT LED or BLOWER 2 SELECT LED. The actual running
blower is indicated by the corresponding BLOWER 1 RUN LED or BLOWER 2
RUN LED. The control software automatically turns on both blowers if the coolant
temperature rises beyond designated limits. Both blowers will stay on until coolant
temperature is OK and the RESET key is pressed.

Note The selected blower will continue to run as long as it maintains the correct
coolant temperature. It is a good practice to alternate the lead blower (one or two) at
regular intervals to ensure that the bridge has reliable backup cooling capacity and to
even the wear on the blowers.

RPM SETPOINT MOTOR RPM LOAD AMPS LOAD KW LOAD VOLTS

DC VOLTS SOURCE PF LOAD PF LOAD HP SOURCE VOLTS TABLE

DIAGNOSTIC READOUT LCI COOLING SYSTEM

READY RUN FAULT ALARM PUMP PUMP BLOWER BLOWER

1 2 1 2
RUN RUN RUN RUN
1
CLRALL
DIAGS 2 3 DATE LOCAL REMOTE PUMP PUMP BLOWER BLOWER
MODE MODE 1 2 1 2
SELECT SELECT SELECT SELECT
4 5 6 INC

7 8 9 DEC

MODE HELP ESCAPE ENTER ENTER LOCAL LOCAL CHAN RESET

ENTER 0 PASS SPEED START STOP OFF
LMPTST CLEAR WORD REFER

Figure 5. OC2000 Cooling System Display

GEH-6374A Innovation Series LCI Liquid Cooling System • 9

Heat Exchanger Installation

Overview
When an external heat exchanger is provided, either water-water or water-air,
mounting and plumbing at the site will be required. The LCI cooling system requires
ultra-high purity water in order to function correctly. Water purity will be
compromised by any contaminates which make their way into the heat exchange
cooling loop. For this reason it is very important that the recommendations in this
section concerning exchanger installation, materials used, and cleaning be followed.
Failure to follow these guidelines can result in startup delays, frequent deionizer
replacement, and extensive damage to the LCI.

Contamination introduced into the system from the heat

exchanger cooling loop can settle throughout the bridge and
be impossible to remove.

Plumbing on the customer’s Prevention is the only way to keep contamination from negatively affecting LCI
side of a water-water performance for years to come. These guidelines apply to piping between the heat
exchanger should conform to exchanger and the LCI pump panel.
the customer’s specifications
not this guide.

Materials
Suitable material for piping and fittings include Type K or L copper tube, copper-
base alloys, stainless steel, or schedule 80 CPVC. To avoid rust contamination, do
not use steel or cast iron pipe or fittings. There is no restriction on the type of flux,
solder, or glue that can be used, however, keep flux to a minimum to avoid excessive
contamination.

Cleaning
Clean all metal pipe and fittings before assembly by wiping their interior with a non-
residue solvent such as Xylol (Xylene) to remove oil, solder flux, and any other
debris.

Note Do not attempt to clean CPVC piping with Xylol. Instead, use soap and then
rinse thoroughly with water.

Flushing
Complete the entire installation with the exception of the final connections to the
LCI pump panel. Blow out any remaining dust or construction debris from the entire
heat exchanger loop with compressed air before making the final connections to the
LCI pump panel.

Stress Relief
Rubber hose and rubber vibration isolators are not required, but can be used if the
manufacturer confirms its compatibility with water and propylene glycol. Use
accepted alignment, strain relief, and expansion practices to prevent stressing system
components.

10 • Innovation Series LCI Liquid Cooling System GEH-6374A

 Allowable Pressure Drop
To keep pressure drop within the acceptable limit, make sure that field-installed
piping complies with the length restrictions as follows:
Maximum total length: 75 ft for 1.5-in nominal diameter
200 ft for 2-in nominal diameter
Elbows: Count as 2 ft each
Ball valves: Count as 7 ft each

Heat Exchanger Elevation

The heat exchanger is normally mounted with its base at or below the elevation of
the drive.
It can be mounted higher than the drive, including on the roof above the drive. The
limitation is the reservoir vent must be above the elevation of the highest point in the
cooling system. The objective is to avoid spillage from the vent in the event of an
extended shut down or venting at some other location.
An alternate approach is to route the reservoir vent to an auxiliary reservoir to
accommodate the heat exchanger and external plumbing located above the reservoir
vent.
The elevation should be kept to a minimum. In no case can the top of the heat
exchanger or any other piping be higher than 26 feet above the base of the drive
(about 20 feet above the reservoir).

Note Heat exchanger performance is reduced above 5000 feet altitude and requires
a special design.

Drain-Back Provision

The heat exchanger is usually mounted at the same elevation

as the drive. If the heat exchanger is mounted above the
drive, coolant draining back into the system from the heat
exchanger can overfill the reservoir upon shutdown.

Provide for drain-back of coolant from the heat exchanger by:

• Extending the reservoir vent to an elevation above the heat exchanger
or
• Using an auxiliary reservoir to hold the additional volume
Using an auxiliary reservoir requires calculating the total volume of drain-back from
the heat exchanger and piping located above the top of the reservoir. Coolant volume
for the type K copper piping connecting the system to the heat exchanger is as
follows:
Volume Diameter
0.089 gal/ft 1½-inch
0.156 gal/ft 2-inch

The dimensions for the various heat exchangers used with this system are defined in
GE drawing 323A1318AA. The volumes for the standard redundant-blower heat
exchangers are shown on the heat exchanger's nameplate. Use the nameplate volume
when calculating any drain-back volumes.

GEH-6374A Innovation Series LCI Liquid Cooling System • 11

 General Mechanical Provisions
Observe the following guidelines when installing piping:
• Use drip loops to prevent water on the pipe exterior from entering the
equipment.
• Provide drain and vent valves at all low and high points to facilitate filling and
draining.

Liquid-to-Air Heat Exchanger Option

Observe the following guidelines when installing this optional heat exchanger:
• Do not obstruct heat exchanger airflow. (Care must be taken to prevent the
cooling fins from becoming obstructed with foreign material.)
• Do not locate the equipment so that it intakes hot air exhausted from some other
equipment.
• Provide at least 1½ fan diameters of clearance to the heat exchanger inlet and
exhaust it away from walls that might cause the air to re-enter.
• Locate the blower above any anticipated snow level.

Liquid-to-Liquid Exchanger Option

If a remotely mounted Robertshaw temperature regulating valve is used, install it as
shown in GE drawing 238B4861, Sheet 2 for liquid-to-liquid heat exchangers.

Note This valve is not supplied by GE. It must be furnished by the user and picked
to operate within the cooling system requirements and meet the environmental
conditions of the site location. Its function is to limit coolant requirements and to
possibly reduce/eliminate manifold sweating during temperature and humidity
extremes.

The use of a thermowell is The dimensions shown (238B4861 sheet 2) for the sensing bulb are for the
recommended so that the thermowell supplied with the valve. The sensing bulb can be installed in any position
coolant does not have to be from vertical to horizontal. If the bulb is installed away from vertical, the arrow
drained if the sensing bulb and/or UP markings on the positioning disk must point UP. The top (threaded end)
has to be removed. should be approximately the same elevation as the valve actuator. Do not install the
sensing bulb below horizontal or with the threaded end below the bulb.

12 • Innovation Series LCI Liquid Cooling System GEH-6374A

Coolant Mixture
The drive's normal operating environment temperature ranges from 0 to 40 °C (32 to
104 °F). The coolant is a water and propylene glycol mixture that prevents freezing
with lower ambient temperatures.
The system should initially be charged with a mixture of distilled, de-mineralized, or
deionized water and pure propylene glycol. Makeup coolant (coolant added to adjust
the coolant concentration) must be a similar mixture to maintain the desired freeze
protection. Depending upon the coolant quality and cleanliness of the heat exchanger
installation, initial charging of the system can require up to 24 hours for the coolant
resistivity to exceed the alarm level. Distilled water (100%) may be used if there is
no chance of freezing.

For freeze protection, use only pure propylene glycol

without additives. Do not use automotive antifreeze or any
type of corrosion inhibitors since this contaminates the
deionizer.

Use propylene glycol from GE Industrial Systems (GE stock number

278A2175FUP1) or Propylene Glycol USP/FCC from Fisher Scientific Company.

Propylene Glycol Concentration

Too much propylene glycol in the mixture reduces cooling
system performance. Be sure to keep it at the minimum
percentage required for freeze protection. The heat dissi-
pation system is fully rated up to a maximum of 52%
propylene glycol.

The concentration of propylene glycol can be selected for as much as 8 °C (15 °F)
above the minimum anticipated temperature since slushing occurs before the coolant
freezes solid.
Typical concentrations of propylene glycol in water with some slushing between the
two listed temperatures are:
30% −13 to −22 °C (8 to −7 °F)
40% −21 to −29 °C (−6 to −21 °F)
52% −35 to −43 °C (−31 to −46 °F)

Figure 6. Refractive Indices for Aqueous Propylene Glycol Solution at 77 °F (25 °C)

GEH-6374A Innovation Series LCI Liquid Cooling System • 13

 Maintaining Coolant Concentration
Water evaporation increases the propylene glycol concentration over time. To keep
coolant freeze protection within the desired range, periodically check the propylene
glycol concentration by doing the following:
The American Optical model 1. Use a refractometer to determine the refractive index of the coolant.
7181 refractometer, for
2. Use the curve of Figure 6 to determine the existing propylene glycol concentra-
example, is portable, requires
tion.
only a few drops of fluid for
testing, and needs no adjust- 3. Add either distilled water or propylene glycol as appropriate.
ment for fluid temperature.
4. Check the concentration again to make sure it is within the correct temperature
parameters.

Note Adding a large quantity of makeup coolant can cause a momentary drop in
coolant electrical resistance and trigger an alarm. Unless extreme contamination has
occurred, the deionizer soon restores nominal resistance. A brief drop in coolant
resistance does not harm system operation.

Startup Procedure
This equipment contains a potential hazard of electrical
shock or burn. Only those who are adequately trained and
thoroughly familiar with the equipment and the instructions
should install, operate, or maintain this equipment.

Ø To startup the coolant system using the Datapanel

1. Before filling the cooling system, jog the pump motor and check rotation by
noting the motor blower rotation direction.

Incorrect rotation can cause the pump impeller to unscrew

on the pump shaft and jam against the pump housing.
Do not run the pump dry for more than a few seconds or
seal damage can result.

2. Make sure that the carbon filter and deionizer are in place in the deionizer loop.
3. Make sure that all external piping connections have been made and tested for
leaks.
4. Fill the reservoir to the full mark with a deionized or distilled water and
propylene glycol mixture in the correct proportion for freeze protection, as
determined from Figure 6.
5. Turn all valves to the ON position.
6. The temperature modulating valve has a manual override to force coolant to the
heat exchanger if the valve fails or if the ambient temperature is below 27 °C
(80 °F). Switch the modulating valve to manual.
7. Cycle the primary pump on to purge air from the system.

Do not empty the reservoir and risk running the pump dry.

14 • Innovation Series LCI Liquid Cooling System GEH-6374A

 8. Stop the pump and refill the reservoir. Record the volume of coolant required to
fill the system for future reference.

Note When the pump is stopped, the reservoir level can rise as coolant flows back
from components above the reservoir. Do not fill the reservoir past the full mark.

9. Repeat the fill and pump cycle until all air is purged from the system and the
reservoir level is stabilized.
10. Air is vented from the pump and deionizer to the reservoir. The bridge and heat
exchanger can have additional manual or continuous vents to the reservoir. Open
these vents to speed purging air, but be careful to avoid losing coolant and
contaminating electric circuits.
11. Slowly close and open the outlet valve on the primary pump. The differential
pressure switch is factory set for 7 psig (48 kPa). Verify that the backup pump
comes online before the outlet valve is completely closed.
12. The system should automatically engage the alternate pump when the LEAD
pump stops. Check to make sure that this process works in both directions, as
follows:
a. Turn off the primary pump using its Pump Starter switch and read the
Datapanel to confirm that an automatic transfer is made to the backup
pump. Then turn the primary pump back on and pushing the RESET button.
Read the Datapanel to confirm that the backup pump is still the LEAD
pump.
b. Turn off the secondary pump using its Pump Starter switch and read the
Datapanel to confirm that an automatic transfer is made to the primary
pump. Then turn the secondary pump back on and push the RESET button.
Read the Datapanel to confirm that the primary pump is still the LEAD
pump.
13. Check the system's lead/lag pump controls as follows:
a. Verify pump transfer by pressing the F2 PUMP SELECT key to switch the
PUMP LEAD from #1 pump to #2 pump and back to #1 pump.
b. With the #1 pump selected as PUMP LEAD, verify automatic transfer to the
#2 pump by slowly closing the outlet valve on the #1 pump as in step 12.
c. Transfer PUMP LEAD status back to #1 pump by pressing the F2 PUMP
SELECT key.
d. Turn off the #1 pump using its Pump Starter switch and read the Datapanel
to confirm that an automatic transfer is made to the backup pump.
e. Repeat the automatic transfer test, starting with step b and the #2 pump
selected.
14. If the system has lead/lag blower controls (only in systems that use liquid-to-air
heat exchangers), check them as follows:
a. Verify blower transfer by switching from #1 blower to #2 and back to #1
blower.
b. With the selector switch set for #1 blower, verify automatic transfer to the
#2 pump by opening the breaker on #1 blower.
c. Repeat the automatic transfer test, starting with step b and the selector set
for #2 blower.

Note The overtemperature switch is factory set to alarm at 68 °C (155 °F) and fault
at 77 °C (170 °F). It should not require adjustment.

GEH-6374A Innovation Series LCI Liquid Cooling System • 15

 15. Check all fittings and hose connections for leaks.
16. Verify the water to propylene glycol mixture.
17. Return the temperature-regulating valve to automatic.

Routine Maintenance

Maintaining the Liquid Cooling System

Periodically is defined as one Periodically check the following items to make sure the liquid cooling system is
month. properly maintained:
• Check the propylene glycol concentration and replenish the coolant, as
necessary.
• Keep the cooling system free from contamination.
• Keep the reservoir covered.
• Clean the strainers.
• Check the coolant resistivity. The life of the carbon filter and deionizer depends
upon the operating temperatures and quality of makeup coolant. If possible, they
should be replaced before the coolant reaches the 1-megohm/centimeter alarm
level.

The deionizer tank should be refurbished by an authorized

service center or replaced with the recommended spare part.
Severe damage to the equipment can result.

• Check all hose connections for leaks. Repair any coolant leaks promptly. The
recommended repair procedure on the 3/8 in bridge coolant hoses is to re-
terminate the hose using two stepless ear clamps of the type originally supplied
with the drive (see Table 2). Cut off the portion of the hose under the old clamps
before making a new connection.

Note Do not use an adjustable, radiator type clamp on the 3/8 in bridge hose. This
type of clamp is sharp and not perfectly round.

• Check the radiator on liquid-to-air heat exchangers. Remove any paper or debris
blocking the radiator.
• Check bridge clamp pressure (source bridge and load bridge)

Table 2. Recommended Spare Parts

Description Part Number Quantity

Blue Hose 278A2175PUP1 50*
Black Hose Clamp 278A2175RYP1 12
Clear Hose Clamp 305A6482P4 8
Blue Hose Clamp 305A6482P5 24
Filter Wrench 278A2175VNP4 1
Pincer Hose Clamp Tool 305A6482P2 1

*1 = 1 foot (50 = 50 feet)

16 • Innovation Series LCI Liquid Cooling System GEH-6374A

Removal and Replacement Procedures

Carbon Filter and Deionizer Cartridge Replacement

Note When a carbon filter is supplied, replace the carbon filter and deionizer
cartridge as a pair.

Ø To replace the deionizer cartridge

1. Close ball valve on supply 3/8 in supply line to the deionizer cartridge and
carbon filter pair.
2. Detach input and output 3/8 in lines from the low spillage couplings (see Figure
7). These couplings are hand operated, and mounted in a position to prevent the
reversal of the input and output lines.
3. Remove the 3/8 in nuts on the clamp, and then remove the clamp.
4. Lift out the expended deionizer cartridge.
5. Put in the new deionizer cartridge.

Note All deionizers, regardless of the external cartridge configuration, use the same
mixed bed resin: Ionic NM-60/SG manufactured by Sybron Chemicals Inc.,
Birmingham, NJ 08011 USA. You may contact a local supplier for a new or
refurbished deionizer or purchase from GE Industrial Systems or the following
supplier: (GE part number 323A2419)
Water Chemistry Inc.
3404 Aerial Way Drive
Roanoke, VA 24018
Phone: (540) 989-0400

6. Attach input and output 3/8 in lines to the couplings.

7. Replace the clamp, and the 3/8 in nuts that hold it in place.
8. Replace the activated charcoal filter.

Filter Replacement (If Supplied)

Ø To replace the filter
1. Replace the deionizer cartridge.
2. Unscrew the filter housing (see Figure 7).
3. Replace expended filter element with new AMETEK EPM-10 cartridge by
contacting:
AMETEK
Plymouth Products Inc.
502 Indiana Avenue, PO Box 1047
Sheboygan, WI 53082-1047
www.plymouthwater.com
Phone: 1 (800) 222-7558
Fax: (920) 457-6652
4. Open the ball valve on 3/8 in supply line to the deionizer cartridge and filter
pair.

GEH-6374A Innovation Series LCI Liquid Cooling System • 17

 Figure 7. Typical Deionizer Cartridge Flow and Filter

Strainer Cleaning
Open the drain valve on the strainer unit (see Figure 8). Debris that has lodged
against the strainer is then flushed out.

DRAINS
STRAINER

Figure 8. Strainer

Coolant Pump Replacement

This equipment contains a potential hazard of electric shock

or burn. Only adequately trained persons who are
thoroughly familiar with the equipment and the instructions
should install or maintain this equipment.

Ø To Remove Coolant Pump

1. Get an assistant to help with the replacement (two persons are needed).
2. Turn off and lock out the start-up switch that supplies 460 V ac power to the
subject pump.
3. Open electrical hookup box at pump motor (see Figure 9).
4. Check power at pump to make sure it is off.

18 • Innovation Series LCI Liquid Cooling System GEH-6374A

 5. Disconnect all wires.
6. Turn off supply and discharge valves for pump.
7. Remove the supply and discharge hoses.
8. For the top pump only:
a. Clamp the pump vent hose leading to the reservoir shut using the pinch-off
tool
b. Disconnect hose from pump
9. While someone else holds the failed pump and motor assembly, unfasten the 1/2
in hex head bolts that secure the bracket to the cabinet. (The bolt attaches to
cage nuts on the other side of the cabinet wall.)

Note Some models of the pump panel require GE part number 323A5715AHP7 3-
hp pumps to be reconfigured for top pump replacement. These pumps are shipped in
a configuration that matches the bottom pump. The following procedure details how
to rotate the discharge for top pump replacement in these models.

Pump Vent Electrical

Hookup

1/2 " Bolts

Bracket

Figure 9. Pump and Motor Assembly

Ø To rotate discharge connection on 323A5715AHP7 pumps for top

pump replacement only (required in certain pump panels)
1. Stand the replacement pump on end with the impeller end up.
2. Remove the casing bolts with a 6 mm Allen wrench and carefully lift off the
casing.
3. Examine the o-ring casing seal for any damage and ensure that the o-ring is in
position on the motor adapter and that the sealing surfaces are free from dirt or
debris.

Impeller surfaces are sharp. Keep o-ring and hands away to

avoid damage or injury.

4. Rotate the casing 180° and carefully position it over the adapter.
5. Reinstall the casing bolts and torque them to 5 − 6 ft lbs with a 6 mm Allen
wrench. (Torque these bolts in a star pattern or sequence.)

GEH-6374A Innovation Series LCI Liquid Cooling System • 19

 Ø To install new coolant pump
1. While someone else holds the replacement pump and motor assembly in place,
fasten the 1/2 in hex head bolts that secure the bracket to the cabinet.
2. For the top pump only, connect and unclamp the pump vent hose leading to the
reservoir.
3. Attach the hoses.
4. Turn on all valves nearest pump.
5. Reconnect all wires at the electrical hookup box.
6. Turn on the 460 V ac supply power.
7. Check all connections for leaks.

Long-Term Storage
Ø To prepare the coolant system for drive shutdown periods of six
months or longer
1. Drain the system of all coolant.
2. Close the valves to isolate the pumps, then blow out all lines with compressed
air.
3. Drain all components, such as the pump.
4. Clean all strainers.
5. Cap all open lines.

Warranty Terms
Product warranty information, including warranty period and parts and service
coverage is defined at the time of sale. This information is included with customer
documentation, but can also be obtained from the nearest GE sales office or GE sales
representative, if needed.

Note Standard warranty is 18 months from shipment or 12 months from when

power is first applied, whichever comes first.

Parts still under warranty may be obtained directly from the factory. Refer to the
section How to Get Help.
Renewal Parts (spares or those not under warranty) should be ordered by contacting
the nearest GE Sales or Service Office. Be sure to include the following when
ordering any warranty or renewal parts:
• Complete part number and description
• Drive serial number
• Drive Material List number

20 • Innovation Series LCI Liquid Cooling System GEH-6374A

 Time Limitations and Warranty
The above times and conditions apply to shipping and storage duration of up to one
year. Longer times can require additional treatment.

Note It is important that the specifications defined in this publication be followed at

all times. Failure to do so voids the equipment warranty.

How to Get Help

If help is needed beyond the instructions provided in the documentation, contact GE
as follows:
GE Industrial Systems
Product Service Engineering
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
“+” indicates the
international access code Phone: + 1 800 533 5885 (United States, Canada, Mexico)
required when calling from + 1 540 378 3280 (International)
outside of the USA. Fax: + 1 540 387 8606 (All)

GEH-6374A Innovation Series LCI Liquid Cooling System • 21

Notes

g
GE Industrial Systems
Rev. B: 2000-06-26 General Electric Company
Supersedes Original: 1997-11-26
 2000 by General Electric Company, USA.
1501 Roanoke Blvd.
All rights reserved. Salem, VA 24153-6492 USA
22 • Innovation Series LCI Liquid Cooling System GEH-6374A
Koenig Turning Gear M392

GT_KoenigM392_01-14 GE Energy Learning Center Proprietary 1

GE Title or job number
1/17/2014
COMPONENTS
 Pawls Engaged – Turning Gear Shaft Starts Sliding Component Moves Into
To Rotate Engagement With Generator Coupling

Fully Engaged And Transmitting Torque To The Generator Coupling And Shaft. Once Generator Shaft
Speed Exceeds Turning Gear Speed, The Sliding Component Will Move Back And The Pawls Will Be
Retracted By Centrifugal Force. At Generator Shutdown The Pawls Engage And TG Starts Initiating
Sequence 1 – 2 – 3 and TG Drives Generator Shaft.
Tab 20
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THIS DRAWING SHALL BE REVISED IN ITS ENTIRETY.
ALL SHEETS OF THIS DOCUMENT ARE THE SAME REV DESCRIPTION DATE APPROVED
REVISION LEVEL AS INDICATED.

REVISION DESCRIPTION IS FULLY STATED ON

LAST SHEET OF THE DOCUMENT.

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A UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

SIGNATURES DATE
GE POWER & WATER GENERAL ELECTRIC COMPANY
DRAWN KUMAR S 20SEP12 Schenectady, NY - USA
TOLERANCES ON:
2 PL DECIMALS ± CHECKED SEE PLM
3 PL DECIMALS
ANGLES ±
FRACTIONS ±
± PROJ ENG
ARUN SANKAR 20SEP12 ONE LINE DIAGRAM
PROJECT
ISSUED SEE PLM GAS TURBINE
THIRD ANGLE PROJECTION C COPYRIGHT " " GE POWER & WATER (USA), LLC AND/OR ITS AFFILIATES. FIRST MADE FOR: 324X039 MLI: 0444
All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical
Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their SIZE CAGE CODE DWG NO
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed
MADE FOR
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authorized in writing by the General Electric Company, GE Power & Water (USA), LLC and/or its affiliates.
COMBINED CYCLE POWER) SCALE NONE IPS# 720103 SHEET 1

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C COPYRIGHT " SIZE CAGE CODE DWG NO
" GE POWER & WATER (USA), LLC AND/OR ITS AFFILIATES.
GE POWER & WATER GENERAL ELECTRIC COMPANY
All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
Schenectady, NY - USA
Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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C COPYRIGHT " SIZE CAGE CODE DWG NO
" GE POWER & WATER (USA), LLC AND/OR ITS AFFILIATES.
GE POWER & WATER GENERAL ELECTRIC COMPANY
All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
Schenectady, NY - USA
Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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C COPYRIGHT " SIZE CAGE CODE DWG NO
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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
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affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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C COPYRIGHT " SIZE CAGE CODE DWG NO
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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
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Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
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Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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C COPYRIGHT " SIZE CAGE CODE DWG NO
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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

105T6628
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Information that belongs to the General Electric Company, GE Power & Water (USA), LLC and/or their
affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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" GE POWER & WATER (USA), LLC AND/OR ITS AFFILIATES.
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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

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affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed DRAWN KUMAR.S
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authorized in writing by the General Electric Company, GE Power & Water (USA), LLC and/or its affiliates. ISSUED SEE PLM SCALE SHEET 10

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All rights reserved. The information contained herein is GE Power & Water Generator Proprietary Technical

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 Simplified EX2100e Control Maximum Case Major Functional Components

8 EX2100e Excitation Control for 100 mm, 77 mm, 53 mm, and 42 mm Thyristor Systems
g EX2100 Digital Exciter Overview GE Power Systems

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g GE Power Systems

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g GE Power Systems

Excitation System Basics

Steady State Role of Excitation System

• Allows power transfer across the air gaps by maintaining the magnetic field.
• Maintains magnetic field for all load condition via regulating generator
terminal voltage.

Special note:
Exciter does not control real power (MW - controlled by prime mover torque)
Exciter controls reactive power (MVARs when on-line, Voltage when off-line)

Steady State Operation

• Generator Vee Curve is best representation of steady state operation
Lagging Current, Over-excited, push VARs onto system
Leading Current, Under-excited, pull VARs off the system

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g GE Power Systems

Excitation System Basics

Transient Performance

During transient events the excitation system tries to maintain synchronism by

changing field voltage.

AVR controller regulates to terminal voltage by increasing or decreasing field

voltage. An Over-excited generator will push VARs onto the system & an Under-
excited generator will consume VARS from the system.

Example:
A large motor starting on the system will consume VARs which will decrease
system voltage, however, the exciter responds by over-exciting the field (forcing
the field voltage higher!).
This pushes VARs onto the system to maintain generator terminal voltage.

Also, during faults the excitation system will need to respond and maintain
synchronism long enough for system relays to operate.
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g GE Power Systems

What is the purpose of the excitation system?

Provide current to create a magnetic field
How many amps at full load?
See Generator nameplate
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g Rating - Nameplate GE Power Systems

Siddhirganj - Bangladesh

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g GE Power Systems

What is the value of rated Generator Terminal voltage?

See the Generator Nameplate data
Which box is the generator breaker? STATOR
See Electrical One Line diagram

What does the term “On Line” mean? ROTOR

Generator Breaker Closed

What is max Vt allowed?

Terminal Voltage (V)t
Rated plus 5%

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g Excitation Electrical One - Line GE Power Systems

Where does the exciter

get the power to create
the DC current?

Separate feed from 4160V

Station Service

Siddhirganj – Bangladesh

Electrical one line

105T6628
Sheet 5
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g GE Power Systems

To Generator Collector Rings

+ _ EX2100 System Components

Medium Voltage
41A 41B
Breaker
Two Excitation Incoming AC
Power Conversion Transformer Power
Modules (PCM) A.K.A.
(6) Thyristors each 41 AC PPT

M1 M2 C Keypads

MarkVI Power
<HMI> Supplies
55555
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g GE Power Systems

EX2100 System Components

¾ Power comes from the station service, via a Medium voltage breaker
and an excitation transformer.
¾ The low voltage circuit breaker (41AC) functions as a disconnect
switch only
¾ The power to the generator rotor is DC, the incoming power is AC,
Thyristors in the PCM are used to convert AC to DC
¾ Contactors 41A and 41B connect the exciter (PCM ) to the collector rings.
¾ The Redundant Controllers M1 and M2 regulate the PCM thyristors.
M1 is the primary controller and M2 is in standby.
¾ The operator can change the level of excitation from the HMI or the
excitation panel touchscreen.
¾ Controller C monitors M1 and M2 and initiates protective responses if
system conditions exceed defined boundaries
¾ Each Core has a separate DC Power Supply

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g GE Power Systems

The EX2100 Cabinet is divided into 3 sections

- Control Cabinet

- Power Conversion Cabinet

- Auxiliary Cabinet

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g Control Core GE Power Systems

Local Keypads

Control Core, M1, M2 & C

M1 is default

C is protection, 2/3 voting

M1 &M2 communicate direct

W/MarkVI via Ethernet network
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g Power Supplies GE Power Systems

Each Core is fed with a separate

DC Power Supply

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g Power Conversion Cabinet GE Power Systems

Bridge 2 Fans

Bridge 1 Fans

41a and 41b contactors

Disc, a.k.a. 41ac

M1 Bridge

M2 Bridge

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g GE Power Systems

Auxiliary Cabinet

• Provides support equipment

for the exciter and generator.
• Equipment includes:
– De-excitation Module
– Shaft Voltage Suppression
(SVS) Module
– Field Flashing (applicable)
– AC Line Filtering
– Ground Detection Interfacing
– High Voltage Interfacing

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g GE Power Systems

The EX2100 is normally operated from the HMI via the turbine control system.
The operator must select the exciter automatic
regulator or manual regulator.

1) What does the exciter automatic regulator

try to control constant?
Generator Terminal Voltage
2) What does the exciter manual regulator
try to control constant?
Generator Field Voltage

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g Excitation HMI Control Screen GE Power Systems

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g GE Power Systems

When the Generator is OFF LINE:

1) An increase in fuel causes an increase in:

SPEED

2) An increase in excitation causes an increase in:

Vt Terminal Voltage

When the Generator is ON LINE:

1) An increase in fuel causes an increase in:

Watts

2) An increase in excitation causes an increase in:

Vars

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g GE Power Systems

GENERATOR CAPABILITY AND

LIMITERS
Vars (Q)

• Under Excitation Limit (UEL)

Rated Field Current
Rated PF – 5 User defined points
OEL – Straight-line between
points
Rated Stator Current• Over Excitation Limit (OEL)
Lag – Protects Generator Field
Watts (P) Winding
– Coordinated with V/Hz
Lead
UEL

End-Iron Heating

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g GE Power Systems

Generator Maximum
PF = Imaginary
Lag Rotation

Vars Limit due to Field Over

Heating
Turbine Minimum
PF = 1
Watts Turbine Maximum

Under
Reactive Limit due to Core End Heating
Amperage
Limit (URAL)

PF =
Lead Generator Maximum
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g GE Power Systems

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g GE Power Systems

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g GE Power Systems

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g GE Power Systems

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g GE Power Systems

End

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 GEI-100787D

EX2100e Excitation and LS2100e Static

Starter Control Systems
Touchscreen Local Operator Interface
Instruction Guide

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications,
and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected
herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to
the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced
herein.

GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this
document does not provide any license whatsoever to any of these patents.

GE provides the following document and the information included therein as is and without warranty of any kind, expressed
or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.

For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.

Revised: July 2013

Issued: Nov 2010

© 2010 – 2013 General Electric Company, All rights reserved.

___________________________________
* Indicates a trademark of General Electric Company and/or its subsidiaries.
All other trademarks are the property of their respective owners.

We would appreciate your feedback about our documentation.

Please send comments or suggestions to [email protected]

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be used,
shown, reproduced, or disclosed outside of GE without the express written consent of GE.
Document History
Document Date Update Description
EX2100e Control Changed how to set the 100% value from the Display High Limit
Touchscreen Main Screen parameter field to the value of application block variables, KYPD_
Features BARGRAPH_1_UNIT and KYPD_BARGRAPH_2_UNIT.
GEI-100787D July 2013
Configuration Settings Added an Attention to notify the user to check the task bar and
close any other applications or command prompt windows that are
running before running the command, DoThisOnTS.

2 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Safety Symbol Legend

Indicates a procedure, condition, or statement that, if not

strictly observed, could result in personal injury or death.

Warning

Indicates a procedure, condition, or statement that, if not

strictly observed, could result in damage to or destruction of
equipment.
Caution

Indicates a procedure, condition, or statement that should be

strictly followed to improve these applications.

Attention

Instruction Guide GEI-100787D 3

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 To prevent personal injury or damage to equipment, follow all
GE safety procedures, Lockout Tagout (LOTO), and site safety
procedures as indicated by Employee Health and Safety (EHS)
guidelines.
Warning

This equipment contains a potential hazard of electric shock,

burn, or death. Only personnel who are adequately trained and
thoroughly familiar with the equipment and the instructions
should install, operate, or maintain this equipment.
Warning

Isolation of test equipment from the equipment under test

presents potential electrical hazards. If the test equipment
cannot be grounded to the equipment under test, the test
equipment’s case must be shielded to prevent contact by
personnel. To minimize hazard of electrical shock or burn,
Warning approved grounding practices and procedures must be strictly
followed.

To prevent personal injury or equipment damage caused by

equipment malfunction, only adequately trained personnel
should modify any programmable machine.
Warning

Always ensure that applicable standards and regulations are

followed and only properly certified equipment is used as a
critical component of a safety system. Never assume that the
Human-machine Interface (HMI) nor the operator will close a
Warning safety critical control loop.

4 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
Contents
1 Overview......................................................................................................................................................6
2 EX2100e Touchscreen Operation.......................................................................................................................8
2.1 Common Status Indicators.........................................................................................................................8
2.2 Main Screen ...........................................................................................................................................9
2.3 Setup Screen......................................................................................................................................... 12
2.4 Alarm History Buffer Screen.................................................................................................................... 14
2.5 Control Functions Screen ........................................................................................................................ 15
2.6 System I/O Status Screen ........................................................................................................................ 16
2.7 Bridge I/O Status Screen (Static Exciters Only) ........................................................................................... 17
3 LS2100e Touchscreen Operation ..................................................................................................................... 18
3.1 Common Status Indicators....................................................................................................................... 18
3.2 Main Screen ......................................................................................................................................... 19
3.3 Setup Screen......................................................................................................................................... 22
3.4 Alarm History Buffer Screen.................................................................................................................... 24
3.5 Cooling Status Screen............................................................................................................................. 25
3.6 LSTB I/O Status Screens......................................................................................................................... 26
3.7 LSGI I/O Status Screen........................................................................................................................... 27
4 Installation .................................................................................................................................................. 28
5 Configuration .............................................................................................................................................. 30
5.1 Enable the Touchscreen .......................................................................................................................... 30
5.2 Customize Touchscreen Display ............................................................................................................... 31
5.3 Touchscreen Configuration ...................................................................................................................... 31
6 Specifications .............................................................................................................................................. 36
7 Diagnostics and Troubleshooting..................................................................................................................... 37
7.1 Connecting to the Controller Web Server.................................................................................................... 38
7.2 Touchscreen Refresh .............................................................................................................................. 38
7.3 Touchscreen Command Prompt ................................................................................................................ 38
7.4 Network Search..................................................................................................................................... 38
7.5 Software Input Panel (SIP) ...................................................................................................................... 39
7.6 Touchscreen Restart ............................................................................................................................... 39
7.7 Touchscreen Calibration.......................................................................................................................... 40
7.8 Task Bar Options ................................................................................................................................... 41
8 Replacement................................................................................................................................................ 42
8.1 Handling Precautions.............................................................................................................................. 42
8.2 Replacement Procedures ......................................................................................................................... 42
9 Ordering ..................................................................................................................................................... 44

Instruction Guide GEI-100787D 5

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
1 Overview
The EX2100e excitation and LS2100e Static Starter control systems local operator
interface, the touchscreen, displays local operation status and provides basic operating
controls. The touchscreen is a 142.2 mm (5.6 in) diagonal display component that may be
mounted on the control cabinet door. The display is a standard touch panel computer
running Windows® CE-5.0 or CE-6.0 operating system.

Advantech™ Model Number GE Part Number †

TPC-66T 336A4940HPP05
TPC-61T 336A4940HQP05KIT
† Although 336A4940HPP05 and 336A4940HQP05KIT are physically interchangeable,

each model requires a different configuration before one can be used to replaced another.
Any replacement must be configured with the correct Ethernet settings before it can be
applied.

The touchscreen uses a standard web browser that links the Ethernet network to a web
server running on the Universal Stand-alone version B (UCSB) controllers of the control
systems. For redundant EX2100e control systems, the touchscreen automatically links to
the active controller (M1 or M2). The touchscreen is configured using the ToolboxST*
application, which is used to configure all GE control parameters.

Touchscreen features include the following:

• Displays the operating state of important variables and functions

• Control and testing of system functions
• Password protection prevents unintentional and unauthorized operation of
touchscreen functions

6 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 EX2100e Control Touchscreen Main Screen

LS2100e Control Touchscreen Main Screen

Instruction Guide GEI-100787D 7

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
2 EX2100e Touchscreen Operation
This section describes the features of the touchscreen that are specific to the EX2100e
excitation control system. Diagnostic screens vary depending on the specific product but
can be typified by the following information:

• After making any changes to the touchscreen configuration in the ToolboxST

application, perform a build and download to update the controller web server so the
changes will take effect on the touchscreen.
• The programmable text fields on the touchscreen are configured using the ToolboxST
application fields. Any text may be entered in these fields, including non-English
text, subject to the fonts available. Text is not affected by the language selection on
the Setup screen.
• The length of text in the text field must be kept short enough to fit the available field
width. If the screen displays field overruns or text does not fit the physical screen
size, shorten the text that is causing distortion.

2.1 Common Status Indicators

Status indicators are available on all touchscreen screens, along the right edge of the
screen.
Status Indicators
Status Indicator Description
Displays which master is the active controller, M1 or M2.
A green background indicates not running, and a red background indicates running.
Heart beats (toggles sizes) to indicate there are active communications within the controller.

Displays when faults are present:

None (OK), alarm (ALM), or trip (TRIP)

Indicates a limiter function is active.

The background color changes from green to yellow.
Indicates the exciter is in Auto (A) or Manual (M) regulator mode

Indicates the exciter is online (closed) or offline (open)

Indicates the locked or unlocked status of the touchscreen.

When locked, the touchscreen is in View Only mode. When the correct password is entered on the Setup
screen, the touchscreen is unlocked and the control functions are enabled. If a control item is pressed
when the touchscreen is locked, the indicator flashes red to indicate that the function is disabled until the
password is entered. Refer to the section, Setup Screen.
Press the GE logo in the upper left corner of the display to refresh the screen. This is useful for
re-establishing communications following a disruption, such as a controller restart or temporary loss of
network connectivity.
Advances to the next screen or returns to the main screen.

8 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 2.2 Main Screen
The touchscreen main screen displays the following:

• Descriptive name of the associated controller, providing visual confirmation that the
touchscreen is connected to the intended controller
• Two controller variables in bar graph and numerical format (specific variables can be
configured but primary status variables, such as field voltage and current, are
typically displayed)
• Configuration of nine controller variables in numerical format
• Items that allow basic exciter control functions (when the padlock indicator has been
unlocked using the proper password entry on the Setup screen)

Main Screen

Instruction Guide GEI-100787D 9

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Main Screen Features
Item Description
Displays the site and/or unit name.
To enter text in this field, from the ToolboxST General tab Tree
(Main screen subtitle field)
View, select Requisition Info and Process Application
property. Refer to the figure, Main Screen Subtitle Field.
Bar graphs display the values for variables KYPD_BARGRAPH_
1 and KYPD_BARGRAPH_2.
The text is set in the Description parameter field and the 100%
value is set by the value of application block variables, KYPD_
BARGRAPH_1_UNIT and KYPD_BARGRAPH_2_UNIT. Refer to
the figure, Main Screen Displayed Variables.
The bar is green in the range –5 to 105% and yellow outside that
range.
In the application block, the corresponding variable, KYPD_
BARGRAPH must be driven by the desired exciter variable.
Refer to the figure, Touchscreen Application Block.
These nine controller variables and text are controlled by the
variables KEYPAD_VARIABLE_1 through KEYPAD_
VARIABLE_9.
The application block logic must drive the Keypad_ variables with
the desired exciter variable. The default precision is set at 2 but
may be changed in the Precision property.

Starts and stops the exciter.

When the exciter is running, STOP displays with a red
background. When the exciter is stopped, START displays with a
green background. The exciter sequencer takes some time to
transition between states.
Indicates the voltage raise and lower functions.
To change the voltage settings, press and hold, or press
repeatedly.
These indicators are grayed out when the control functions are
locked by password protection.
Toggles the controller between AUTO and MANUAL modes of
operation (must be enabled by the password).

Sends a Reset Alarms command to the controller.

The background color is red when trips are present, yellow when
alarms are present, and green when no faults are present.

10 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Main Screen Subtitle Field

Main Screen Displayed Variables

Instruction Guide GEI-100787D 11

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Touchscreen Application Block

2.3 Setup Screen

The Setup screen displays the following:

• Login password to change the privilege level from View Only to Operator
• Logout options (the operator can either logout immediately or set automatic logout
after a selectable interval of inactivity)
• Control name as user-configured in the ToolboxST application
• Language and fixed text fields

Setup Screen

12 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Setup Screen Features
Item Description
Login password entry field.
To unlock the padlock indicator and enable control functions, enter a
six-digit password matching what is set in the ToolboxST
configuration. Press SELECT to highlight the first cell. Press ↑ or ↓
to scroll to the correct value. In succession, press SELECT and set
the remaining digits. Once the sixth digit is displayed, press ENTER
to send the password to the controller. If the password is valid, the
privilege changes to Operator, the padlock indicator unlocks, all
touchscreen functions are enabled, and the entered password is
encrypted.
Press ESCAPE at any time during the procedure to end password
login and encrypt entered digits.
Refer to the section, Configuration.
Displays the touchscreen user privilege level.
The privilege level defaults to View Only unless the user has logged
in with the correct password, in which case the privilege level
displays as Operator. In View Only mode, the touchscreen will not
send any exciter control commands to the controller; the user can
view the exciter status, but not change it.
Sets the login automatic timeout.
Press SELECT to highlight the field, and ↑ or ↓ to change the auto
logout interval from 5 minutes up to 1 day. Press ENTER to accept
the new choice, or ESCAPE to remain at the prior setting.
User logout.
Press SELECT and ENTER to force an immediate log off from the
Operator privilege level back to View Only.
If logoff is not desired, press SELECT or ESCAPE.
Displays the same text as the Main Screen . Refer to the section,
Main Screen.
Sets the touchscreen language preference.
Press SELECT to highlight the Language field, and ↑ or ↓ to scroll
through the available choices. Press ENTER to accept the new
choice, or ESCAPE to remain at the prior setting.
This field does not affect the configured text fields programmed in the
ToolboxST application. Set the language in the ToolboxST application
field to the preferred language.
Press to navigate through screens.

Instruction Guide GEI-100787D 13

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 2.4 Alarm History Buffer Screen
The Alarm History Buffer screen displays the following:

• Up and down arrows to view the full depth of the buffer

• RESET ALARMS to send a reset command to the controller and clear alarms (same as
RESET on the main screen)

Alarm History Buffer Screen

14 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 2.5 Control Functions Screen
The Control Functions screen displays the following:

• Status of various exciter control functions, such as up and down arrows to scroll
through available functions
• Control functions, including:
Refer to GEH-6676, Power
− Power System Stabilizer (PSS) enable or disable
System Stabilizer (PSS) for an
− Volt-amperes reactive (VAR) control enable or disable
EX2100 and EX2100e
− Power Factor (PF) control enable or disable
Excitation Control.
− Reset of a potential transformer (PT) fault
− Reset of blocked M1/M2 controller transfers
− Manual transfer of controllers between M1 and M2
− Field Ground Detector enable or disable
− Initiate Field Ground Detector test, which normally displays ground resistance

Note During the Field Ground Detector test, which takes 10-15 seconds to
complete, a test resistance of approximately 5000 Ω is displayed for about 5
seconds if the ground detector is operating properly.

• TOGGLE to change the state of control functions when the touchscreen is in

Operator privilege level.

Ø To change the state of control functions

1. Using the up or down arrows, highlight the desired function.
2. Press TOGGLE to view and select the alternate choices. The cell flashes while
displaying the potential command.
3. Press ENTER to send the highlighted command to the exciter, or scroll away from
the function to leave it unchanged.

Control Functions Screen

Instruction Guide GEI-100787D 15

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 2.6 System I/O Status Screen
The System I/O Status screen displays the status of system related I/O functions, which
includes the following:
Refer to the system elementary • Input voltage on the two customer analog inputs to the EX2100e System I/O
and the ToolboxST application Interface (ESYS)
settings for the application
• Output voltage on the four analog outputs from the ESYS
specific function and
configuration of each signal. • Input status of the seven general-purpose contact inputs to the ESYS, and the
customer 86 lockout and 52G (online) breaker inputs
Refer to GEI-100772, EX2100e
• Output state of the four general-purpose relays and two trip relays on the ESYS, and
Excitation Control System I/O
the state of the 41DC field output contactor and the 53A and 53B flashing contactors
Interface (ESYS) Module
Instruction Guide. • Status of up to four control power sources as follows:
− For the LS2100e static exciter, normally up to two ac inputs and one dc input to
the EDIS, and the state of the optional auxiliary 28 V dc supply
− For the EX2100e regulator system , up to four 28 V dc control power supplies
• Fields to customize the application by changing the Description field of the
corresponding ToolboxST application variable (subject to the available fonts and
space constraints of the text field on the screens)

System I/O Status Screen

16 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 2.7 Bridge I/O Status Screen (Static Exciters Only)
The Bridge I/O Status screen (included only in static EX2100e control systems) allows
status display of bridge related functions for each bridge in the power section of the
exciter, including the following:
• Numbers 1-4 indicates which bridge is being displayed (determined by the
ToolboxST application parameter NumTotalBridges). Press SELECT BRIDGE to
cycle between available bridges.
• Bridge gating status (ACTIVE if cells are being gated by the controller)

Refer to GEI-100776, EX2100e • Status of the fan control outputs from the EX2100e Bridge Interface (EBRG) board.
Excitation Control Bridge Depending on the application, these control up to four fan starters per bridge.
Interface (EBRG) Board
• Speed in RPM of the fans (up to four per bridge), based on once-per-revolution
Instruction Guide.
pulses from the hall effect current sensors in the fans

Refer to the system elementary • Bridge temperature, based on the thermistor mounted in each bridge
for specific details. • Output values from the two analog output drives on the EBRG (the output variables
are configured by ToolboxST application parameters)
• Status of up to four contact inputs, such as line filter blown fuse detectors
• Fields that may be customized

Bridge I/O Status Screen

Instruction Guide GEI-100787D 17

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
3 LS2100e Touchscreen Operation
This section describes the features of the touchscreen specific to the LS2100e control
system. Diagnostic screens vary depending on the specific product but are typified by the
following information:

• After making changes to the touchscreen configuration in the ToolboxST application,

perform a build and download the application to update the controller web server so
the changes will take effect on the touchscreen.
• The programmable text fields on this screen are configured in the ToolboxST
application fields. Any text entered into these fields, including non-English text, is
subject to the fonts available to the ToolboxST application and touchscreen computer.
This text is not affected by the language selection on the Setup screen.
• The length of text in the programmable text fields must be kept short enough to fit
the available field width. If the screen displays field overruns or does not fit the
physical screen size, shorten the text that is causing distortion.

3.1 Common Status Indicators

Status indicators are available on all touchscreen screens, along the right edge of the
screen.
Status Indicators
Status Indicator Description
Heart beats (toggles sizes) when there are active communications within the controller.

Displays when faults are present:

None (OK), alarm (ALM), or trip (TRIP)

Indicates the LS2100e control is online (closed) or offline (open)

Indicates the locked or unlocked status of the touchscreen.

When locked, the touchscreen is in View Only mode. When the correct password is entered on the
Setup screen, the touchscreen is unlocked and the control functions are enabled. If a control item is
pressed when the touchscreen is locked, the indicator flashes red as a visual indication that the
function is disabled until the password is entered. Refer to the section, Setup Screen.
Press the GE logo in the upper left corner to refresh the screen. This is useful for re-establishing
communications following a disruption, such as a controller restart or temporary loss of network
connectivity.
Displays the state of the LS2100e control, such as ready to start, not ready to start, or currently running

Advances to the next screen or returns to the main screen.

18 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 3.2 Main Screen
The touchscreen main screen displays the following:

• Descriptive name of the associated controller, providing visual confirmation that the
touchscreen is connected to the intended controller
• Two controller variables in bar graph and numerical format (specific variables can be
configured, but primary status variables such as field voltage and current are
typically displayed)
• Configuration of six controller variables in numerical format
• Items that allow basic exciter control functions (when the padlock indicator has been
unlocked using the proper password entry on the Setup screen)

Main Screen

Instruction Guide GEI-100787D 19

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Main Screen Features
Item Description
Displays the site and/or unit name.
To enter text in this field, from the General tab Tree View, select
(Main Screen Subtitle field)
Requisition Info and Process Application. Refer to the figure,
Main Screen Subtitle Field.
Bar graphs display the values for the variables KYPD_
BARGRAPH_1 and KYPD_BARGRAPH_2.
The text is set in the Description parameter field and the 100%
value is set in the Display High Limit parameter field. Refer to the
figure, Main Screen Displayed Variables.
The bar is green in the range –5 to 105% and yellow outside that
range. In the application block, the corresponding variable,
KYPD_BARGRAPH, must be driven by the desired exciter
variable. Refer to the figure, Touchscreen Application Block.
These six controller variables and text are controlled by variables,
KEYPAD_VARIABLE_1 through KEYPAD_VARIABLE_6.
The application block logic must drive these Keypad_ variables
with the desired exciter variable. The default precision is set at 2
but may be changed in the ToolboxST application Precision
property.
Displays the operation status of the LS2100e control as READY,
NOT READY, or STOP.
When the LS2100e control is running, STOP displays with a red
background, and READY displays with a green background when
the LS2100e control is stopped.
Displays the cooling status, such as coolant temperature and
resistivity, coolant level and pressure, and pumps and blowers

Displays when Cooling Status is pressed to alternate the active

pump between PUMP 1 and PUMP 2.

Displays when Cooling Status is selected to alternate the active

blower between BLOWER 1 and BLOWER 2.

Sends a Reset Alarms command to the controller.

The background color is red when trips are present, yellow when
alarms are present, and green when no faults are present.

20 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Main Screen Subtitle Field

Main Screen Displayed Variables

Instruction Guide GEI-100787D 21

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Touchscreen Application Block

3.3 Setup Screen

The Setup screen displays the following:

• Login password entry to change the privilege level from View Only to Operator
• Logout options (the operator can either logout immediately or set automatic logout
after a selectable interval of inactivity)
• Control name as user-configured in the ToolboxST application
• Language and fixed text fields

Setup Screen

22 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 Setup Screen Features
Item Description
Login password entry field.
To unlock the padlock indicator and enable control functions, enter a
six-digit password matching what is set in the ToolboxST
configuration. Press SELECT to highlight the first cell. Press ↑ or ↓
to scroll to the correct value. In succession, press SELECT and set
the remaining digits. Once the sixth digit is displayed, press ENTER
to send the password to the controller. If the password is valid, the
privilege changes to Operator, the padlock indicator unlocks, all
touchscreen functions are enabled, and the entered password is
encrypted.
Press ESCAPE at any time during the procedure to end password
login and encrypt entered digits.
Refer to the section, Configuration.
Displays the touchscreen user privilege level.
The privilege level defaults to View Only unless the user has logged
in with the correct password, in which case the privilege level
displays as Operator. In View Only mode, the touchscreen will not
send any exciter control commands to the controller; the user can
view the exciter status, but not change it.
Sets the login automatic timeout.
Press SELECT to highlight the field, and ↑ or ↓ to change the auto
logout interval from 5 minutes up to 1 day. Press ENTER to accept
the new choice, or ESCAPE to remain at the prior setting.
User logout.
Press SELECT and ENTER to force an immediate log off from the
Operator privilege level back to View Only.
If logoff is not desired, press SELECT or ESCAPE.
Displays the same text as the Main Screen. Refer to the section,
Main Screen.
Sets the touchscreen language preference.
Press SELECT to highlight the Language field, and ↑ or ↓ to scroll
through the available choices. Press ENTER to accept the new
choice, or ESCAPE to remain at the prior setting.
This field does not affect the configured text fields programmed in the
ToolboxST application. Set the language in the ToolboxST application
field to the preferred language.
Press to navigate through screens.

Instruction Guide GEI-100787D 23

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 3.4 Alarm History Buffer Screen
The Alarm History Buffer screen displays the following:

• Up and down arrows to view the full depth of the buffer

• RESET ALARMS to send a reset command to the controller to clear alarms
• HOME to return to the main screen

Alarm History Buffer Screen

24 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 3.5 Cooling Status Screen
The Cooling Status screen displays the following:

• Status of cooling system functions, such as coolant temperature and resistivity,

coolant level and pressure, and which pumps and blowers are running
• Pump and blower selection (enabled when the touchscreen is in Operator privilege
level). Press CHANGE PUMP to alternate between pumps and CHANGE
BLOWER to select blowers.
• HOME to return to the main screen

Cooling Status Screen

Instruction Guide GEI-100787D 25

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 3.6 LSTB I/O Status Screens
Refer to GEI-100780, LS2100e The I/O Status Screens display the status of the Static Starter Control I/O Terminal Board
Static Starter Control I/O (LSTB) functions, including the following:
Terminal Board (LSTB)
Instruction Guide. • Status of the 32 digital inputs to the LSTB
• Output state of the 14 relays on the LSTB
Refer to the system elementary
and the ToolboxST application • Variables that are configured using the ToolboxST application Description field
settings for the specific (subject to the available fonts and space constraints of the text field on the screens)
function and configuration of
each LSTB signal. Note For crossover (XOVR) configuration applications, additional screens for LSTB-2
are available that are similar to the LSTB-1 screens displayed in the following figures.

LSTB–1 Digital Inputs Screen

LSTB–1 Relay Outputs Screen

26 GEI-100787D EX2100e and LS2100e Control Systems Touchscreen Local Operator Interface
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
 3.7 LSGI I/O Status Screen
Refer to GEI-100781, LS2100e The LSGI I/O Status screen displays the status of the Static Starter Gating Interface
Static Starter Control Gating (LSGI) related functions, including the following:
Interface (LSGI) Board
Instruction Guide. • Analog input and output values
• Status of the source breaker 52SS and instantaneous overcurrent (IOC) fault
• Reference speed and voltage values

LSGI System I/O Status Screen

Instruction Guide GEI-100787D 27

GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
Tab 21
 GEK 116371
March 2009

GE Energy

Hydrogen–Cooled Generators
Electrical and Mechanical Features Axial Fan – Conventionally Cooled –
2-Pole

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 116371 Hydrogen–Cooled Generators

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

TABLE OF CONTENTS

I. GENERAL DESCRIPTION OF GENERATORS ...................................................................... 4

II. STATOR FRAME AND SPRING MOUNTING......................................................................... 4

III. STATOR CORE ............................................................................................................................. 5

IV. STATOR WINDING ...................................................................................................................... 6

V. RESISTANCE TEMPERATURE DETECTORS ...................................................................... 8

VI. HIGH–VOLTAGE BUSHINGS AND CURRENT TRANSFORMERS................................... 8

VII. GAS COOLERS............................................................................................................................. 8

VIII. STATOR VENTILATION........................................................................................................... 8

IX. GENERATOR ROTOR (MECHANICAL AND VENTILATION) .......................................... 10

X. FIELD WINDING AND RETAINING RINGS .......................................................................... 11

XI. COLLECTOR AND COLLECTOR CONNECTIONS ............................................................. 11

XII. BRUSHES AND BRUSH HOLDER RIGGING......................................................................... 11

XIII. END SHIELDS AND BEARINGS ............................................................................................. 11

LIST OF FIGURES

Figure 1. Typical Hydrogen–Cooled Turbine–Generator........................................................................ 4

Figure 2. Typical Stator Punching ........................................................................................................... 5
Figure 3. Stator End Winding Structure .................................................................................................. 6
Figure 4. Typical Stator Winding End Turns and Connections for a Two–Pole, Hydrogen-Cooled Gen-
erator ........................................................................................................................................ 6
Figure 5. Armature Conductors Assembled in a “Roebel” Bar............................................................... 7
Figure 6. Once-through Flow Ventilation System for Hydrogen–Cooled Generator.............................. 9
Figure 7. Forward Flow Ventilation System for Hydrogen–Cooled Generator ...................................... 9
Figure 8. Typical Assembled Rotor ......................................................................................................... 10
Figure 9. Rotor Slot Assembly ................................................................................................................ 10

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEK 116371 Hydrogen–Cooled Generators

I. GENERAL DESCRIPTION OF GENERATORS

The conventionally–cooled hydrogen turbine–generator is completely enclosed for operation with hydro-
gen gas as the cooling medium. The ventilation system is completely self-contained including gas coolers
and fans. The separately excited rotating field, driven by the turbine, rotates inside the stationary armature
and is supported by bearings located in the end shields mounted on the generator frame. See Figure 1.

Figure 1. Typical Hydrogen–Cooled Turbine–Generator

The machine is designed to operate continuously, delivering power from the armature terminals, with pro-
visions being made for maintaining the hydrogen pressure and purity and for supplying cooling water and
lubricating oil. Temperature detectors and other devices are installed in and connected to the machine to
permit the measurement of the winding and hydrogen temperatures, and the hydrogen pressure and purity.
The generator is constructed to withstand all normal conditions of operation without harm. The stator cas-
ing is constructed to limit the destructive effects of an internal hydrogen explosion.

II. STATOR FRAME AND SPRING MOUNTING

The stator frame consists of a gastight cylindrical casing of welded plate construction, reinforced internally
in the radial direction by stationary web plates, and in the axial direction by key bars and braces.

The stator core punchings are held permanently under pressure in the axial direction of the generator. The
stator core is also spring mounted to isolate both radial and tangential vibration of the stator core from the
outer frame. With core motion limited to safe magnitudes, this results in low frame vibration and quiet
operation.

The stator frame is supported on the foundation by either of two methods – leveling devices (‘fixators’) or
plates and shims. Leveling devices serve the dual purpose of uniformly supporting the generator and pro-
viding adjustable vertical alignment capability. Heavy structural end shields which contain the generator
bearings are bolted to the ends of the frame. The frame also serves as the support and enclosure for the
gas coolers. All end shields, coolers, access ports, etc., are carefully sealed to prevent leakage of hydrogen
from the generator. Lifting trunnions bolted to the sides of the frame are provided for attachment of lifting
slings to rig the generator. These trunnions are removeable to meet transportation and site installation space
requirements.

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

III. STATOR CORE

The stator core is made up of segmented, insulated punchings of high-quality, electrical grade silicon steel.
These punchings are assembled in an interleaved manner on dovetail–shaped keys integral with the key bars
and are separated into packets by space blocks to provide ventilation ducts. The punchings are stamped
from thin steel sheets and contain open-end slots for the armature bars with dovetail slots for wedges to hold
the armature bars in place as shown in Figure 2. The assembled punchings are clamped into a stiff cylin-
drical core by pressure applied through ductile cast–iron end flanges from nuts torqued onto the threaded
ends of the key bars. Pressure is applied to the teeth by nonmagnetic steel fingers located under the end
flanges. In order to reduce heating from rotor end leakage flux and its associated electrical losses occurring
at the ends of the stator core, the end packets of punchings are stepped back to increase the gap between the
punchings and the rotor. The punching insulation is a thermo-setting varnish which maintains its insulating
properties at temperatures above the normal operating range of the generator.

CAUTION

Since the keybars, in effect, short across the back edges of the punchings, it is
essential to avoid damaging the core at the inside diameter or tooth tips. If the
punchings are burred or shorted together at the tooth tips, this would permit cir-
culating currents, induced by the magnetic flux in the core, resulting in a hot spot
and possible damage to the core.

Figure 2. Typical Stator Punching

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 116371 Hydrogen–Cooled Generators

Figure 3. Stator End Winding Structure

IV. STATOR WINDING

The stator winding, Figure 4, is composed of insulated bars assembled in the stator slots, joined at the ends
to form coils, and connected in the proper phase belts by connection rings. Each phase is split into groups
of coils.

Figure 4. Typical Stator Winding End Turns and Connections for a Two–Pole, Hydrogen-Cooled
Generator

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

The phases are electrically spaced every 120 degrees. The stator bars are composed of insulated copper
conductors (strands) transposed by the “Roebel” method so that each strand occupies, for an equal length
along the bar, every radial position in the slot. This arrangement avoids circulating current loss which
would otherwise be present under load conditions due to the self-inductive distribution of magnetic flux in
the coil slot. See Figure 5 for details of the transposed bar. The armature bars are held in the core slots by
Textolite wedges driven into the dovetail slots also shown in Figure 5.

The stator bar is composed of several individually insulated transposed strands. A micapal insulation sys-
tem is applied to form the main “ground wall” insulation of the stator bar. This insulation system consists of
several layers of mica tape bonded with a thermosetting binder. The result is a high density, high dielectric
strength system which has high mechanical strength throughout the operating range of temperature. The
bars, with a composite buildup of layers of tape applied, are placed in a tank and subjected to vacuum,
pressure, and heating cycles, to remove the volatiles, compact the system to eliminate voids and cure the
binder.

Armor tape is applied to the core portion of the stator bar to protect the bar from abrasion in the slot. Corona
suppressors control the voltage gradient along the outer surfaces of the stator bars between the end of the
conductive slot armor and the series loops.

Suppressors are designed to eliminate electrical tracking and discharges at normal operating voltages and
at test voltage levels. A high resistance semi-conductive cross grading paint is applied to the end arms to
suppress corona activity in the end winding during high potential tests and during operation.

Stator coil ends are covered either with mica insulation (phase straps) or a cap (series loops), after which
they are sprayed with epoxy paint. These end turns are securely restrained by the binding bands, which are
molded fiberglass rings supported from the stator core flanges (Figure 3). The fiberglass ties, space blocks,
and conformable material are bonded with thermosetting resin.

Figure 5. Armature Conductors Assembled in a “Roebel” Bar

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 7

GEK 116371 Hydrogen–Cooled Generators

V. RESISTANCE TEMPERATURE DETECTORS

Resistance type temperature detectors (RTDs) are located between top and bottom bars in each phase of
the armature windings to measure the temperature of the windings at the points of highest operating tem-
perature.

Gas temperature detectors are provided to measure the inlet and outlet gas temperatures of each of the
coolers. The leads from the detectors are brought out through a gastight gland in the generator frame
and connected to DIN connectors in outdoor rated junction boxes for connection to the turbine-generator
control. A more complete description of the resistance temperature detectors, their locations, and their
connections in the electrical junction boxes is provided in separate drawings and instructions listed in the
Table of Contents of the composite book for the set.

VI. HIGH–VOLTAGE BUSHINGS AND CURRENT TRANSFORMERS

The main armature leads typically exit the top of the generator frame (through the terminal plates by means
of gastight, high-voltage bushings) for gas turbine applications, and the bottom of the frame for steam tur-
bine applications. On most generators, connections are provided at the collector end (opposite the turbine
coupling).

The bushings consist of one–piece porcelain insulators containing a copper conductor. The terminals at
each end of the bushing are silver–plated. To minimize induced current losses and heating caused by load
current in the leads, the terminal plates are made of nonmagnetic material. Drains are provided to prevent
accumulation of oil or water around connections at the bottom of the frame.

Bushing–type current transformers, if used, are mounted on the high–voltage bushings. A more complete
description of these transformers is provided in separate instructions listed in the Table of Contents of the
composite book for the set if the generator is provided with bushing–type current transformers.

VII. GAS COOLERS

Generator gas coolers are mounted either vertically in the cooler towers at the four corners of the frame, or
horizontally in the base of the stator frame. Water pipe connections are made externally at the bottom of
each cooler (when vertically mounted). Hydrogen sealing is by a compression packing at the ‘floating’ end
and by a pumped seal at the ‘fixed’ end. A more complete description of these seals is provided in separate
instructions listed in the Table of Contents of the composite book for the set.

WARNING

SERVICING OR REPAIRING THE COOLER WHILE THE GEN-

ERATOR IS OPERATING WITH HYDROGEN IN THE CASING
IS EXTREMELY HAZARDOUS AND SHOULD NOT BE AT-
TEMPTED.

VIII. STATOR VENTILATION

The rotor fans provide the pressure rise required for the ventilation of the generator. The fans are axial flow
type with individual blades fastened to fan hubs near the ends of the rotor. Inlet nozzles may be used to
control the entrance condition of the gas to the fans.

8 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

The stator ventilating circuit is shown in Figure 6 and Figure 7. There are two types of circuits used on
conventionally cooled generators. The particular circuit utilized is based upon overall optimization of the
specific generator architecture.

1. In the ‘once-through’ ventilation scheme, hydrogen is forced by the fans into the gas gap and then
directed radially outward through the radial gas ducts between the punching packets all along the
stator core. Hot gas is directed to the coolers. After the heat is removed, cold gas returns to the rotor
fans and recirculates.

Figure 6. Once-through Flow Ventilation System for Hydrogen–Cooled Generator

2. In the ‘forward flow’ ventilation scheme, hydrogen is forced by the fans into the gas gap, and around
behind the stator core. The stator is divided axially into sections by the web plates so that in some
sections cold gas is forced from the outside of the core toward the gas gap through the radial gas ducts
between the punching packets, and in other sections it passes from the gas gap toward the outside of
the core through the radial gas ducts. Cooling gas is conducted through tubes or ducts to the proper
section, and hot gas is directed to the coolers. After the heat is removed, cold gas returns to the rotor
fans and recirculates.

Figure 7. Forward Flow Ventilation System for Hydrogen–Cooled Generator

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 9

GEK 116371 Hydrogen–Cooled Generators

IX. GENERATOR ROTOR (MECHANICAL AND VENTILATION)

The construction of the generator rotor is illustrated in Figure 8. The rotor is machined from a single alloy
steel forging which has passed extensive tests to ensure that the forging meets the required physical and
metallurgical properties.

Longitudinal slots, machined radially in the body, contain the field coils. Field coils are held in the slots
against centrifugal force by non-magnetic steel wedges. These wedges are driven into dovetail openings
machined in the rotor slots. The wedges and the coils they hold in place are designed with radial holes that
are aligned together to form numerous radial passages connecting the rotor subslot and the gas gap. Gas
flows axially under the rotor endwindings and on into the subslots and then radially outward through the
radial passages discharging finally into the gas gap. The radial flow of gas removes the heat generated in
the coils. The gas flowing along the gap over the rotor surface cools the rotor externally.

Rotor fans, provided for the ventilation of the generator, are assembled near the ends of the rotor.

Figure 8. Typical Assembled Rotor

Figure 9. Rotor Slot Assembly

10 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

X. FIELD WINDING AND RETAINING RINGS

The field winding consists of rectangular copper bars formed into coils. Several turns in one pair of slots
around one pole form a coil. Several coils are assembled around each pole to form the winding. The
individual turns are insulated from each other. Coils are insulated from the slot wall in the body portion by
molded slot liners, as shown in Figure 9. To provide maximum ventilation and cooling, the end portions
of the field coils are left bare. Molded ring insulation is provided between the coils and the retaining rings,
and epoxy glass blocking is provided in the end windings to separate and support the coils and restrict their
movements under stress from temperature and rotational forces.

The end turns are held in place against centrifugal force by heavy retaining rings machined from high
strength, heat–treated alloy steel forgings which are shrunk and locked onto the rotor body.

XI. COLLECTOR AND COLLECTOR CONNECTIONS

Current is supplied to the field windings through the collector rings which are electrically connected with
the field winding through insulated copper bars assembled in the bored–out center of the rotor forging.
At one end of the connection bars terminal studs, assembled in radial holes in the rotor shaft, connect the
winding to the bars. At the end of the shaft this connection is accomplished using collector studs. The
collector end connections use an elastomeric seal system to contain H2 pressure.

A more complete description of the collector is provided in separate instructions listed in the Table of
Contents of the composite book for the set.

XII. BRUSHES AND BRUSH HOLDER RIGGING

A more complete description of the brushes and brush holder rigging is provided in separate instructions
listed in the Table of Contents of the composite book for the set.

XIII. END SHIELDS AND BEARINGS

The generator rotor bearings, the hydrogen shaft seals, and oil passages for supplying oil to these parts
are contained in the outer end shields. The end shields are split on the horizontal centerline to facilitate
their removal. Joints between the shield halves and between the shields and the stator frame are fitted and
provided with grooves for the insertion of sealing compound to seal the gas in the machine.

The rotor bearings are provided with ball seats to allow accurate alignment of the bearings with the rotor
journal surfaces. A more complete description of the bearings is provided in separate instructions listed in
the Table of Contents of the composite book for the set.

The escape of hydrogen from the generator along the shaft is prevented by a shaft seal attached to each outer
end shield, inboard of the bearing. This arrangement permits inspection of the generator bearings without
removing gas from the machine. A more complete description of the shaft sealing system is provided in
separate instructions listed in the Table of Contents of the composite book for the set.

Both the bearing and the shaft seal housing at the collector end of the machine are insulated from the gen-
erator frame to prevent the flow of shaft currents.

Inner end or ‘gas’ shields are located between the ends of the armature windings and the outer end shields
to separate the gas discharged from the fans from the gas entering the fans.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 11

GEK 116371 Hydrogen–Cooled Generators

GE Energy
General Electric Company
www.gepower.com

12 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

DWG Number 105T6949 Rev - Released 11/5/2012 Page 1 of 1 6,=( ':*12 6+ 5(9

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GE Proprietary Information - Class II (Internal) US EAR - NLR
DWG Number 105T9715 Rev - Released 10/26/2012 Page 1 of 12

SIZE DWG NO SH REV

A 105T9715 1 -
DATE
REV ZONE DESCRIPTION APPROVED
(YYYY-MM-DD)
- Initial Release per ECO0078440 2012-10-25 SEE PLM

THIS DOCUMENT SHALL BE REVISED THIS DRAWING TO BE REVISED IN MICROSOFT

IN ITS ENTIRETY. ALL SHEETS OF THIS WORD ONLY. THE SOURCE FILE IS STORED IN
DOCUMENT ARE THE SAME REVISION A SECURE DATABASE
LEVEL AS INDICATED.

REVISION DESCRIPTION IS FULLY

STATED ON FIRST SHEET OF
DOCUMENT

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIGNATURES & DATES
GENERAL ELECTRIC COMPANY
DRAWN - Flute Yan GE ENERGY GENERATOR
Schenectady, NY, USA
DRAWN DATE (YYYY-MM-DD) – 2012-10-25

CHECKED - SEE PLM

CHECKED DATE (YYYY-MM-DD) - SEE PLM GENERATOR REQUISITION SUMMARY

Siddhirganj 335 MW Combined Cycle Power
ENGR - SEE PLM

ENGRG DATE (YYYY-MM-DD) - SEE PLM

FIRST MADE FOR: 324X039 MLI/COST CODE: C907
ADDITIONAL APPROVALS SIZE CAGE CODE DWG NO
SEE PLM SYSTEM FOR REGISTERED
APPLIED PRACTICES INFORMATION A 105T9715
SIM TO: RDO CODE: SHEET 1 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 2 of 12

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C907 – Requisition Summary Sheets

Customer Name: Isolux Ingenieria S.A

Project Name: Siddhirganj 335 MW Combined Cycle Power

Site Location: Siddhirganj, Bangladeshi

Generator Serial Numbers: 324X039

Generator Model Type: 324-U5XG+ Static Excitation

Generator Electrical Design Number: 720103G2

Gas Turbine DM No. 9FA

Customer Drawing Appliqué

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 2 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 3 of 12

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Generator Performance

These design conditions are for: Base Load

Rating: 332000 kVA

Frequency: 50 Hz

Lagging Power Factor: 0.80

Leading Power Factor: Capability to 0.95

Armature Voltage: 15000 VAC Line to Line RMS

Active Power: 265600 kW

SCR: 0.45

Excitation: 1245 kW 625 V 1992 D.C.Amps

Hydrogen Casing Pressure: 413.7 kPa (g) / 60 PSIG

Maximum Cold Gas temperature at rating point: 40 deg C

Site Elevation: 7.9 m

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 3 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 4 of 12

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A 105T9715 4 -

Line Terminal Configuration

Line Terminal Side
The Direction of the Leads Relative to Collector End is Left Side (Horizontal)

Line Terminal Phase Sequence

Definition of the Phase Sequence:
Voltage Reaches a Positive Maximum in the Order 1,2,3.
Looking at the Leads from The side that they exit the Generator,
The Phase Sequence is:

I1, I2, I3 is Right-Center-Left

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 4 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 5 of 12

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Generator Bearing Lube Oil Piping Connection

Lube oil feed connection on the Left viewed from the collector end
Lube oil drain connection on the Right viewed from the collector end

Generator Rotation Direction

As viewed from the collector end, the generator rotates Counter-Clock-Wise

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 5 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 6 of 12

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A 105T9715 6 -

Site Conditions
Site Elevation: 7.9
Installation: Outdoor
Outdoor ambient temp: Min 8 deg C
Max 40 deg C

Cooling Water System

Closed Loop Cooling Water System Supplied by CUSTOMER
Coolant is 100% Fresh Water
Fouling Factor is 0.001 FF

 Ambient Temperature Cooling Water Temperature

Minimum Day 8 deg C 26 deg C
Maximum Day 40 deg C 46 deg C
Design Condition (GT) 35 deg C 40 deg C

Site Voltages
AC - Three phase 400 VAC
AC - Single phase 230 VAC
UPS - 230 VAC

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 6 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 7 of 12

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Cooler Details
Generator Cooler Construction Materials
90-10 Copper Nickel Tubes
Carbon Steel Cooler Tube Sheet
Carbon w/Epoxy Waterbox & Coupling Flanges

4 Post Mounted Cooler Connections

Cooler Ports on Bottom viewed from the collector end

Cooler Pressure Capability is 861.8 kPa (125 PSI)

Companion Flanges for Cooler Connection
ASME Stamp Required

Space Heaters
Three Phase Stator Heater
Single Phase Collector Heater

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 7 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 8 of 12

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Instrumentation
Temperature Sensors
Bearing Thermocouples are Type K (Chromel Alumel - Dual Element), unless
noted otherwise
Lube Oil Thermocouples are Type K (Chromel Alumel) (Dual Element) unless
noted otherwise
RTDs are 100 Ohm @ 0 C Platinum, 3-wire

Stator Slots Temperature Instrumentation (Dual Element):

12 Stator Slot RTDs
3 Extra Stator Slot RTDs

Stator Core Temperature Instrumentation:

6 Type E TCs

Gas Temperature Instrumentation:

4 Cold Gas RTDs (cooler outlet gas) (Dual Element)
4 Hot Gas RTDs (cooler inlet gas) (Dual Element)
2 Common Cold Gas RTD (Dual Element)
1 Collector Inlet Air RTDs (Dual Element)
1 Collector Outlet Air RTDs (Dual Element)

Bearing and Lube Oil Instrumentation:

2 TCs for CE Bearing Metal, 2 TCs for TE Bearing Metal
1 TC in CE Drain Oil, 1 TC in TE Drain Oil

Vibration Instrumentation
2 Velocity (Seismic) Probes on TE
1 Velocity (Seismic) Probes on CE
2 Single Bently-Nevada 3300 Proximity Probes, 45/45 degree locations on TE
2 Single Bently-Nevada 3300 Proximity Probes, 45/45 degree locations on CE

Flux Probe Permanently Mounted Flux Probe

Liquid Detector
1 Liquid Level Detector Shipped Loose (Dual settings)

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 8 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 9 of 12

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Excitation, Generator Protection, and CT Information

See One-Line diagram

Hydrogen System (For H2 Cooled Gen Only)

Hydrogen Flow Totalizer
Gas Purity Analyzer
Gas Flow Meter
Two Gas Analyzers
Pressure Switches DPDT
Hydrogen Bottle Manifold Not Provided by GE
CO2 Bottle Manifold Not Provided by GE
Gas Dryer Not Provided by GE

Seal Oil Control (For H2 Cooled Gen Only)

Seal Oil Flow Meter
Pressure Differential Gauge

Generator Factory Test and Customer Witness

Customer Witness Point:

Generator Rotor Balance, Over Speed
Gen Rotor HI POT, Insulation Resistance Check
Gen Stator HI POT, Insulation Resistance Check

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 9 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 10 of 12

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A 105T9715 10 -

Other Information
Nameplate Information
GE standard stainless steel nameplate information per IEC

Paint
Epoxy Primer

Maintenance Tools Provided (1 set per site)

Rotor Lifting Slings
Rotor Removal Equipment (Shoes, Pans, Pulling Devices)
Rotor Jacking Bolts
Tools and Wrenches

Transportation
Ship Coolers Installed
Ship Rotor Separate
Ship End Shields Separate
Ship Collector Compartment/Enclosure Separate
Ship with High Voltage Bushings/Leads Installed
Ship with Generator Feet Separate

Special Requirements
Acoustic guarantee (Near Field Avg) w/o barrier wall: 85 dBA
Will there be static start (LCI) applied to this generator? Yes
Are there any special requirements on generator cooler material? No
Is GE required to provide the ASME code stamp certificate? Yes
Are there Lift Oil Provisions for the Generator Bearings? Yes
Generator (Model 324) is manufactured in USA

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 10 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 11 of 12

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A 105T9715 11 -

Customer Drawings
The cycle (weeks) for customer drawings begins from the week of customer kick-off meeting (Oct
5, 2012).

GE Item Description Req. Cycle Time

0070 ELEMENTARY DIAGRAMS - STM 9
0440 DIAGRAM,SCHEMATIC,LOAD EQUIP 17
0444 DIAGRAM,ONE LINE 15
0445 DIAGRAM,INTERCONNECTION 26
0463 DIAGRAM,BLOCK,CABLE 16
4023 DIAG, SCHEM-LCI COOLING LOOP 17
40SS STATIC START DUTY CYCLE 16
A1C0 GEN LAYDOWN SPACE 8
A1D0 ELECTRICAL O/L 10
B6D0 PIPING CONNECTIONS GEN 8
B7P0 LAGGING ARRANGEMENT 8
C184 PROTECTION STUDIES AND RELAY SET 40
C900 EXCITER CONSTANTS 10
C902 GENERATOR PERFORMANCE DATA 6
C907 GEN REQ SUM SHEETS 5
C908 GENERATOR HAZARDOUS AREA MAP 10
C909 GENERATOR RESIDUAL RISK SUMMARY 10
C912 ELECTRIC PANEL RESIDUAL RISK GTG 10
D6B0 ROTOR SHIP DIMS 8
F015 CONTROL COMPT ARR,STATION-SUGG 20
G1C2 O/L, H2 SEAL OIL CONTROL UNIT 8
G1D0 LIQUID LEVEL DETECTOR O/L 8
G1G0 GAS CONTROL VALVES O/L 8
G1H0 H2 CABINET O/L 8
G1J2 FLOAT TRAP MED 8
G2B0 GEN GAS AUX ELEC CONN DIAGRAM 8
G2C0 H2 CONTROL ELEM 8
G2FA GENERATOR P&ID 8
G2RA H2 SYSTEM VALVES 8
G3EA O/L, H2 FLOW TOTALIZER 8
G4JG GENERATOR PIPING O/L 8
G4JX MANIFOLD PURGE CONV. 8
©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

RDO CODE: SHEET 11 of 12

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T9715 Rev - Released 10/26/2012 Page 12 of 12

SIZE DWG NO SH REV

A 105T9715 12 -

STATION DESIGNERS HANDBOOK

This is a compilation of “typical” data, drawings, and instructions that allow the plant designers
to understand the generator configuration and design. It also includes standard design
functional specification recommendations for piping up or applying the GE scope equipment.

Two CD copies of 324 generator designer’s handbook were provided at the Customer Kick-Off
meeting.

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
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GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
A 105T9715
DRAWN - SEE PLM

DRAWN DATE (YYYY-MM-DD) - 120925

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e
VENTILATING SYSTEM FOR HYDROGEN-COOLED GENERATOR

COOLER COOLER

COLD
COLD GAS
GAS

GAS GAP
FAN
FAN
ROTOR

ST_STF11-7_9-12 GE Energy Learning Center STF 11–7

Shaft Grounding System, Operation and Maintenance GEK 116546a

B. Shaft Voltage and Current Monitor, Carbon Brush Rigging

The GE Shaft Voltage and Current Monitor Brush Rigging is comprised of four brushes, mounted on
a special insulating support, located on the turbine end of the generator, see Figure 3.

Figure 3. Typical Ground Brush Rigging with Voltage and Current Monitoring

© 2011 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
 GEK 116362a

g
Revised, May 2009

GE Energy

NOTE:

This document has been modified for training purposes to reflect

site specifc equipment configuration.
Pages 13 - 16 and 21-28 of the original document have been
removed.
This modified document is refered to as ETTgek116362_Pin
GE Energy Technical Training 11/2011

Collector and Carbon Brush Rigging Installation, Operation

and Maintenance

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:
NOTE
Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

TABLE OF CONTENTS

I. INTRODUCTION ....................................................................................................................................... 5
II. SAFETY ....................................................................................................................................................... 5
III. COLLECTOR FLASHOVERS.................................................................................................................. 8
IV. PRE - INSTALLATION AND PLANNING ............................................................................................. 9
A. Collector Inlet ........................................................................................................................................ 9
B. Collector Exhaust................................................................................................................................. 10
C. Ventilation Ducting.............................................................................................................................. 10
D. Maintenance Access............................................................................................................................. 11
E. Electrical Connections ......................................................................................................................... 11
V. INSTALLATION, OPERATION AND MAINTENANCE ................................................................... 11
A. Collector Rings .................................................................................................................................... 11
B. Collector Brush Holders ...................................................................................................................... 12
C. Collector Brushes................................................................................................................................. 29
D. Clearances ............................................................................................................................................ 30
E. Cleanliness ........................................................................................................................................... 32
F. Collector Ring and Brush Vibration .................................................................................................... 34
G. Insulation Electrical Testing ................................................................................................................ 36
H. Collector Hardware.............................................................................................................................. 36
VI. MAINTENANCE INSPECTION SCHEDULE...................................................................................... 37
A. Recomended Spare Parts...................................................................................................................... 37
B. Daily Inspection ................................................................................................................................... 37
C. Weekly Inspection ............................................................................................................................... 38
D. Monthly Inspection .............................................................................................................................. 38
E. Inspections and Servicing During Shutdowns ..................................................................................... 39
VII. RESURFACING COLLECTOR RINGS................................................................................................ 40
A. General................................................................................................................................................. 40
B. Resurfacing Guidelines........................................................................................................................ 40
C. Required Equipment ............................................................................................................................ 43
VIII. TECHNICAL SUPPORT ......................................................................................................................... 43

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

 GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

LIST OF FIGURES

Figure 1. Damage caused by a Flashover............................................................................................................... 8

Figure 2. Brush Wear at Various Levels of Humidity ........................................................................................... 9
Figure 3. Single Box and Clip Brush Holder Assembly ...................................................................................... 13
Figure 4. Single Box and Clip Brush Holder – Brush Wear Gage....................................................................... 14
Figure 5. Single Box and Clip Brush Holder - Press the Button to Remove / Install the Handle ........................ 14
Figure 6. Single Box and Clip Brush Holder - Installing A New Brush .............................................................. 15
Figure 7. Single Box and Clip Brush Holder - Brush Pigtail Properly inserted and engaged around Rivet ........ 15
Figure 8. Single Box and Clip Brush Holder - Spring Plate Tabs engaged in Brush Holder............................... 16
Figure 9. Single Box and Clip Brush Holder - Connection Plate engaged into Contact Clip .............................. 16
Figure 10. Single Plug-In-Cartridge Style Brush Holder Assembly .................................................................... 17
Figure 11. Single Plug-In-Cartridge Style Brush Holder – Brush Wear Gage..................................................... 18
Figure 12. Single Plug-In-Cartridge Style Brush Holder - Brush Holder Handle Installation............................. 18
Figure 13. Single Plug-In-Cartridge Style Brush Holder - Insert Brush Holder into Fixture .............................. 19
Figure 14. Single Plug-In-Cartridge Style Brush Holder - Brush Installation ..................................................... 19
Figure 15. Single Plug-In-Cartridge Style Brush Holder – Proper Shunt Orientation ......................................... 20
Figure 16. Single Plug-In-Cartridge Style Brush Holder - Installing the Brush Holder on the Support.............. 20
Figure 17. Pin Style Magazine Brush Holder— Brushes Installed ...................................................................... 21
Figure 18. Pin Style Magazine Brush Holder — Back View, Handle Removed, Brushes Installed ................... 22
Figure 19. Pin Style Magazine Brush Holder – Brush Wear Gage ...................................................................... 22
Figure 20. Pin Style Magazine Brush Holder – Locked and Unlocked Positions................................................ 23
Figure 21. Pin Style Magazine Brush Holder – Proper Shunt Orientation .......................................................... 23
Figure 22. Box Style Magazine Brush Holder— One Brush Installed ................................................................ 24
Figure 23. Box Style Magazine Brush Holder – Brush Wear Gage..................................................................... 25
Figure 24. Box Style Magazine Brush Holder – Proper Shunt Orientation ......................................................... 25
Figure 25. Plug Style Magazine Brush Holder..................................................................................................... 26
Figure 26. Plug Style Magazine Brush Holder - Brush Wear Indicator............................................................... 27
Figure 27. Plug Style Magazine Brush Holder – Locked and Unlocked Positions.............................................. 27
Figure 28. Plug Style Magazine Brush Holder – Spring Clip Removal............................................................... 28
Figure 29. Plug Style Magazine Brush Holder – Proper Shunt Orientation ........................................................ 28
Figure 30. Collector Brush Rigging Configuration – Washer Shims................................................................... 31
Figure 31. Collector Brush Rigging Configuration – Adjustment Nuts............................................................... 31
Figure 32. Long Term Brush Vibration................................................................................................................ 35
Figure 33. Acceptable Vibration Levels for Generator Collectors....................................................................... 35
Figure 34. Typical Brush Rigging Electrical Test Setup...................................................................................... 36
Figure 35. Grinding on Turning Gear using as Grinding Wheel (left) and Beltsander (right)............................. 41

LIST OF TABLES

Table 1. Typical Collector Sound Power Levels (dB ref 1 picoWatt) at Ventilation Inlet and Outlet................. 10
Table 2. Maximum Allowable Ducting Pressure Drop ........................................................................................ 10
Table 3. Recommended Viscosity Grades for Galvanized Steel Air Filter.......................................................... 33

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

I. INTRODUCTION

Collector systems utilize a rotating slip ring and stationary carbon brushes to transfer the field current
from the stationary exciter to the rotating generator field. Collectors typically utilize a once-through
ventilation system. This ventilation air serves several functions including: cooling of collector
components, dilution of small, potential leaks of hazardous gas (hydrogen filled generators only) and
removal of carbon dust.

Ideal conditions for brush operation would be to run them on highly polished rings of accurate contour
having zero vibration and cooled to temperatures not exceeding 212ºF (100ºC) in a controlled humidity
medium, free from dust and contaminating gases. Though all these conditions cannot be met in actual
operation, the nearer they can be approached, the better. To this end, ample margins are used in the
design of collectors and meticulous care is used in their manufacture. However, there are other factors
upon which good performance depends, including the following:

1. Correct installation and initial operation.

2. Proper collector operating conditions and effective operating maintenance.
3. Thorough equipment servicing and reconditioning during scheduled outages.

WARNING

INSPECTION, OPERATION AND MAINTENANCE SHOULD ONLY BE

PERFORMED BY A QUALIFIED AND TRAINED ELECTRICIAN.

II. SAFETY

WARNING

SERIOUS ELECTRICAL SHOCK CAN OCCUR IF EITHER (1) THE

POSITIVE AND NEGATIVE POLARITY COMPONENTS ARE
TOUCHED SIMULTANEOUSLY, OR (2) EITHER POLARITY OR
GROUND ARE TOUCHED SIMULTANEOUSLY. ROTOR GROUND
FAULT DETECTION EQUIPMENT CAN PROVIDE A VOLTAGE ON
THE RINGS TO GROUND EVEN WHEN THE UNIT IS NOT IN
OPERATION.

WARNING

THE COLLECTOR CONTAINS ROTATING COMPONENTS SUCH AS

THE COLLECTOR FAN, COLLECTOR RINGS AND SHAFT.
POTENTIAL INJURY MAY OCCUR IF THESE COMPONENTS ARE
CONTACTED.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

These instructions do not purport to cover all details or variations in equipment or to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further
information be desired or should particular problems arise which are not covered sufficiently for the
purchaser's purposes the matter should be referred to the General Electric Company.

During installation and maintenance, such as when handling or removing brushes, observation of
appropriate safety precautions for collector and brush rigging maintenance is required. The following are
general safety guidelines with regard to handling or changing brushes, or maintaining the brush rigging,
or the collector rings. They do not purport to cover all conditions and situations with regard to brush
rigging and collector maintenance.

1. Only qualified personnel familiar with the construction and operation of the collector and brush
rigging and the hazards associated with them should install, adjust, operate and /or service this unit.
Read and understand this manual in its entirety before proceeding. Failure to observe this precaution
could result in severe bodily injury or loss of life or damage to the equipment.
Most collector designs contain provisions for a customer-supplied door lock, either on the collector
or on the cab in which the collector is installed. If such provisions are provided, the customer shall
provide a lock to prevent unauthorized access.

2. An insulated handle is provided for changing brushes. Be sure that the brush changing handle and
other equipment coming in contact with brushes or collector rings is clean and dry prior to use.
Failure to do this can result in a serious shock hazard.
3. While maintaining brushes and collector rings, remove any metallic objects (watches, chains, etc.) or
other items, which could come in contact or fall into the brush rigging or rotating collector ring and
fan parts. It is recommended that rubber gloves designed for working on energized electrical
equipment be worn when handling brushes to prevent inadvertent contact with the brush rigging by
either hand. During operation, the brush rigging nominal voltage can vary from 200 to 750 VDC
depending on design and operating conditions; ceiling voltages can be as much as 3+ times higher
than nominal voltage for short periods of time. Where possible, use one hand when working on the
energized collector components. If the brush assembly needs further guidance for installation use an
insulated rod or flat bar with the other hand to guide the brush into the brush holder.
4. The user is responsible for conforming to the applicable local codes and safety regulations when
working on this equipment. This includes, but is not limited to, the proper use and application of
Personal Protective Equipment (PPE).
Noise from the open collector door may reach levels of 100 dBA or higher. Hearing protection
should be worn whenever the door is open. It is recommended that the end user perform a site
acoustic survey to determine the proper amount of PPE that is required.

The collector contains high amounts of electrical energy, thus it has the potential of creating an arc
flash. The proper level of arc flash protection should be worn whenever the collector door is open. It
is recommended that the end user perform an arc flash study to determine the proper amount of PPE
that is required.

5. Keep the components inside of the collector housing very clean. Normal brush wear produces a fine,
conductive dust, which can deposit on insulating surfaces of the brush rigging, collectors, and
housing. Buildup of this conductive dust can result in a shock hazard, even when touching non-
electrical parts, and can cause equipment damage if build-up of dust becomes severe.

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

6. Only GE approved components (collector brushes, brush holders, brush springs, etc…) shall be used.
Use of non-approved collector components may increase the chance of a collector flashover.
Use only the brush holders and springs furnished with or specified for the generator. Do not mix the
constant-pressure holders with any other type. Use only the grade of brush furnished with the
generator unless given other specific instructions by the General Electric Company. Under no
circumstances should brushes of different grades be used on the same collector ring. Failure to
comply will increase the chance of a collector flashover.

7. To minimize exposure to a hazardous condition, always check for severe sparking or other
hazardous condition by looking through the collector door window before opening the door.
8. Normal brush wear produces a fine dust. Over exposure, mainly through ingestion, could lead to
health problems. Refer to the collector brush MSDS sheet for specific details. The ventilation flow
of the collector is adequate to keep this dust concentration below exposure limits.
9. 10. As stated in OSHA industry standard 1910.269, “Before changing brushes while the generator is
in service, the exciter or generator field shall be checked to determine whether a ground condition
exists. Brushes may not be changed while the generator is energized if a ground condition exists.”
GE recommends this practice for all generators to minimize the exposure of personnel to arc flashes.
Reference GEK75512 for General Electrics recommendations on ground faults detection.
10. Ideally, the generator field is a floating circuit such that the voltage magnitude to ground is the same
for both polarities. On older, electromechanical excitation systems the field ground-sensing relay
adds a bias voltage and a resistive ground reference. This would result in a larger voltage to ground
than if the field was floating. The voltage to ground on one pole could be as high as the full field
voltage plus any voltage added by the field ground-sensing system. In addition this circuit adds a
source of current flow to ground. Both the increased voltage and the presence of a current flow to
ground result in an increased risk to the operator. On this type of system an isolation switch can be
utilized to remove the bias voltage and ground reference while changing brushes to reduce this risk.
Newer, digital systems, minimize this risk by utilize a low voltage pulse to sense ground conditions.
With this type of system there is no need to isolate the system when changing brushes.
11. All GE collectors are air-cooled. On hydrogen-cooled generators, there is the potential for a
hydrogen leak to occur, causing hydrogen to enter the collector enclosure. All collectors on
hydrogen-cooled generators utilize a high point vent to minimize the chance of a hydrogen buildup,
should this condition occur. All equipment inside of the collector enclosure is rated to operate in the
presence of a potentially explosive hydrogen mixture. The only potential ignition source within the
collector enclosure is the collector brush to collector ring contact when excitation current is applied.
On most units, excitation current cannot be applied until the generator rotor is at operating speed. In
this condition, the collector ventilation is sufficient to dilute a hydrogen leak to below the lower
explosive limit (LEL). On generators with static start, excitation current is applied before the
generator rotor reaches operating speed. On these units, hydrogen detectors are utilized to prevent
the application of excitation current if a hydrogen concentration approaching the LEL is detected.

WARNING

HYDROGEN DETECTORS MUST BE PERIODICALLY CALIBRATED,

TYPICALLY EVERY 90 DAYS, TO ENSURE PROPER OPERATION.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 7

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

III. COLLECTOR FLASHOVERS

The most serious collector problem is a flashover. A flashover can severely damage the slip ring and
brush rigging assemblies and can result in injuring personnel. Most flashovers can be avoided through the
use of proper preventative maintenance activities.

CAUTION

Lack of proper maintenance is the root cause of most collector flashovers.

The term collector flashover describes the opening of the highly inductive generator field circuit at either
one or both collector polarities. Breakdown of the insulation separating the two polarities can occur but is
typically a very rare occurrence. The open circuit is typically the result of a progressive loss of contact
between the ring and brushes, causing the current to be transferred by arcing across the gap until the gap
becomes too large for the arc to be sustained. This action is similar to very slowly opening a knife switch
in an inductive circuit. On the collector, the arcing itself is the mechanism for increasing the gap and
results in excessive ring and brush holder heating, pitting, and erosion damage.

To compensate for the energy lost during the heavy arcing prior to flashover, the automatic voltage
regulator simply calls for higher exciter output to keep the generator terminal voltage constant. If the
average generator field temperature, calculated using the quotient of excitation voltage to current, both
measured on the brush-rigging side of the collector, is included in the station controls, it can be used to
indirectly detect collector arcing. Collector arcing would result in an erratic and generally higher
indicated generator field temperature. Therefore, erratic behavior of the generator field temperature
should not be automatically regarded as a controls malfunction but should be looked upon as a warning of
possible collector arcing.

The conditions that lead to a flashover are progressive; therefore it is necessary to recognize and heed the
early warning signals during routine maintenance to prevent serious trouble. Severe arcing sometimes can
go on for hours, even days, before the gap increases to the point where the arc breaks down and the field
circuit opens, completing the flashover. Regardless of the cause of the flashover, it takes time for
conditions to deteriorate until the actual flashover occurs. More and more individual brushes become
inactive as they lose contact or their pigtails are burned off until finally the only way for the current to
continue flowing is by arcing across the gaps between the rotating and stationary parts of the collector
assembly. This is the stage during which the rings get pitted, brushes vaporize and brush holders melt
(see Figure 1).

Pin Style Brush Holder Generator Rotor Collector Ring

Figure 1. Damage caused by a Flashover

8 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

The most commonly blamed oversight is a failure to replace worn-down brushes. Extremely high
vibration due to a rough ring, brushes hanging up in holders, cooling air contamination, worn or damaged
springs, slip ring contamination, and severe selectivity may also lead to problems.

Selectivity, which in this context refers to the unwillingness of the parallel brushes to share current
equally, is a natural phenomenon on slip rings. In mild forms selectivity leads simply to high brush wear
on those brushes consistently carrying high current, but it has been found that most brushes go through
cycles of high and low current conduction for an averaging effect. In extreme cases selectivity can render
the overloaded brushes ineffective by burning off their copper pigtails, further overloading the remaining
brushes and thus causing a runaway of this condition. Aggravating circumstances such as high brush
vibration, hung-up brushes, oil contamination, or mixing of brush grades on the same ring are usually
present before extreme cases occur.

IV. PRE - INSTALLATION AND PLANNING

A. Collector Inlet
The collector inlet air can be drawn from either inside or outside of a turbine-generator building. To
optimize brush life collector inlet air shall be kept as cool as possible, 40ºC max recommended.
Based on limited testing, brush wear will increase ~6% for every 5ºC increase in temperature. The air
supply should always remain below the alarm point of 65ºC. Inlet high temperature alarms indicate
an operational issue with the collector and should be investigated immediately. Possible causes of
this alarm are air recirculation or blocked ventilation flow, typically resulting from clogged filters.

To ensure safe operation of the collector, the inlet air source shall be located in a non-rated area. This
is to ensure that the collector inlet air does not contain hazardous gas.

Collector brushes utilize water from the air for lubrication. For proper operation the inlet air should
have an absolute humidity of at least approximately 20 grains of water per pound of dry air, 50 grains
of water per pound of dry air is ideal. Operation at lower absolute humidity levels will increase brush
wear; see Figure 2.

Figure 2. Brush Wear at Various Levels of Humidity

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 9

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

A filter, designed for typical industrial applications, is supplied on the inlet of the collector. High
concentrations (greater than 2,000 mg/m3) of sand or similar particles in the inlet air will require
frequent cleaning of the collector filter. For this condition, a pre-filtering system (not supplied by GE)
may be required. Operation without an adequate filtration system will reduce performance, increase
brush wear and damage collector rings leading to brush bounce.

Hydrogen sulfide, sulfur dioxide, chlorine, fumes from carbon tetrachloride and other air
contaminants can affect brush operation adversely by causing undue concentrations of unwanted
materials in the ring films or brush faces. Such contamination can be reduced by the application of
special chemical filters (supplied by others) containing activated charcoal to the ventilating system.

B. Collector Exhaust
The exhaust temperature of the collector will typically be between 5ºC to 15ºC above the collector air
inlet temperature. A differential temperature alarm is set at a 20ºC rise. Ventilation differential alarms
indicate an operational issue with the collector and should be investigated immediately. A possible
cause of this alarm is blocked ventilation flow, typically resulting from clogged filters. Note: The
filters should be periodically maintained to prevent them from becoming clogged.

The exhaust will contain carbon dust. On hydrogen cooled generators, a hydrogen leak of the
generator could occur causing hydrogen to enter the collector enclosure and become entrained in the
collector exhaust air. At rated speed the collector ventilation is sufficient to dilute a hydrogen leak to
below the lower explosive limit (LEL). Below rated speed, the concentration of hydrogen may reach
the LEL.

C. Ventilation Ducting
Some collector units require ventilation ducting (not supplied by GE). The design of this ducting is
critical for optimum operation. On noise-sensitive installations, the ventilation ducting may require
silencers (not supplied by GE). A blower (not supplied by GE) is required if the pressure drop in the
ducting (including silencers, if supplied) exceeds the allowable drop. Reference Table 1 for estimated
sound power levels and Table 2 for the allowable ducting pressure drop.

Table 1. Typical Collector Sound Power Levels (dB ref 1 picoWatt) at Ventilation Inlet and Outlet
Overall
OCTAVE BAND (HZ) 31.5 63 125 250 500 1000 2000 4000 8000
dBA
Sound Power for Models
67 78 86 90 91 95 95 92 81 100
170A, 7FH2/B, 324, 330H, 390H, 450H
Table 2. Maximum Allowable Ducting Pressure Drop
Model Flow Allowable Pressure Drop
Number (CFM) (Inches of Water)
170A 3500 1.0
7FH2 3500 1.0
324 3500 1.0
390 3500 1.0
330H 3500 1.0
450H 3500 2.5

The collector ducting shall be designed such that recirculation of air between the inlet and outlet does
not occur. Recirculation could result in reduced performance or a safety concern due to hotter inlet
air, ingestion of carbon dust and ingestion of hazardous gas (hydrogen filled generators only).

10 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

D. Maintenance Access
Access to the collector brushes, collector access panels and filters is required for periodic
maintenance. Reference the mechanical outline for the location of these items.

E. Electrical Connections
Electrical connections from the excitation system and for instrumentation are required. Reference the
electrical connection outline for details of these connections.

V. INSTALLATION, OPERATION AND MAINTENANCE

A. Collector Rings
1. Collector Ring Surface Finish

Collector rings should be polished to an eight micro-inch (203 nm) finish. The rings should be
free from markings, rust, dirt and oil. Oil and dirt can be removed with a small amount of
electrical equipment cleaning solvent, after which additional cleaning must be accomplished by
an application of alcohol followed by a dry cloth to remove any remaining moisture. The
cleaning must be done with care to prevent liquid dripping on insulation parts. Avoid handprints
or fingerprints on the rings, because the body moisture left by such an imprint will cause rust. If
any nicks or small upsets in the surfaces on which brushes bear have occurred during handling,
blend them smooth with a hand stone.

2. Collector Ring Film

Formation of ring film is an important factor on which good operation depends. Do not apply
heavy current to raw, unfilmed rings through unseated brushes. Rather, wear the brushes in
during warm-up and stretch out runs so that a seat is formed. It is best to start the initial film at
low current and increase it gradually. If the brush grade is ever changed, it is strongly
recommended that the existing ring film be removed by polishing to let the new brush material
form its own characteristic film. The formation of a good brush film will depend on freedom
from scratches and tears on the ring face and freedom of the air stream from abrasive dust that
can lodge under brushes to score the rings. Ring scratches leave steel in a form that can be
picked up easily by brushes, become concentrated under the action of current flow and form a
metal-to-metal contact. The resulting pinpoint concentration of current when the field is applied
is sufficiently great to cause tiny arcs that produce microscopic pits or holes in the rings that may
or may not be healed over by brush film.

3. Collector Ring Wear

The rate of ring wear may vary greatly depending mainly on the effectiveness of the protective
brush film. Under good conditions the diametrical collector ring wear rate is small, typically
0.001” (0.025 mm) per 1,000 hours. Wear rates of the order of 0.005” (0.127 mm) per 1,000
hours indicate poor collector performance. As a rule, wear rates are not constant and vary
significantly with environment conditions.

Ring wear is due to mechanical abrasion by the brushes and/or electrical (or arc) erosion of steel
by the brush currents. Of the two, the electrical wear is generally the greater. In cases of severe
ring wear, the usual sequence is for mechanical abrasion to wear one or more depressions a few
thousands of an inch deep in the originally round ring surface so that the sliding brush contact
becomes more variable and minute arcing begins to accelerate the wear rate. If allowed to

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 11

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

continue, heat from the arcing raises the brush friction, and tangential chattering of brushes can
begin to chip their edges. As depressions are worn deeper in the rings, accelerating forces on the
brushes become very high so that brush operation becomes unsatisfactory such as sparking and
pitting of the collector ring. In some cases the brushes may even shatter or break.

Ring wear is inherently slightly different for the two polarities. To extend the life of the collector
rings, polarities should be occasionally reversed. This is achieved by reversing cable connections
or changing a link in the solid bus work. A corresponding change in the excitation control
equipment may also be required, especially with static start equipment requiring pole position
sensors.

Periodic collector ring resurfacing by grinding to correct this condition is considered routine
maintenance, and normally collector rings have sufficient stock to last the lifetime of the
generator. If it becomes necessary to resurface the collector ring more frequently than once every
two or three years, the reason for the ring surface deterioration should be sought out and
corrected. It is recommend to resurface the rings if any of the following conditions are present:

a. Collector ring pitting (or frosted surface) in brush tracts, which cannot be removed by normal
cleaning.

b. Excessive brush vibration

c. Excessive radial runout in brush tracks. If the ring contour shows bumps and hollows or flat
spots of 0.002” (0.0508 mm) or over in depth, or radial runout changes more than 0.005”
(0.013 mm) per 3 inches (76 mm) indicator travel around the circumference.

d. Excessive axial run out or taper. If brush tracts are grooved over 0.020” (0.508 mm) deep, or
if there is an axially taper greater than 0.010” per inch. Collector operation is tolerant to
minor taper of the collector rings. Taper has the greatest effect on the support of brushes, i.e.
distance from the ring surface to the brush holder.

The ring diameter can be reduced just to where the original spiral groove remains. The spiral
groove is necessary for satisfactory collector operation. If it appears necessary to reduce the
diameter below that level, General Electric Company has to be contacted. Reference section VII
for information on how to resurface collector rings.

B. Collector Brush Holders

All modern brush holders utilize a constant pressure spring to ensure that a uniform force is
maintained on the top of the brush as it wears down. Depending on the design of the brush rigging
one of the following brush holder designs will be utilized.

When installing brushes, verify that brushes and shunts are not damaged. Verify that each brush
moves freely over its entire length of travel. A brush may be assembled without interference being
noticed, but the brush will not operate properly if it does not move freely. Carbon pathways should be
clean and free of obstructions. Verify that the copper shunts or “pigtails” are fastened to the brush
holder in the proper orientation. An incorrect orientation can limit brush movement.

For pin style brush holders the design clearance between a new brush holes and the pins is from
0.016 to 0.021 inches (0.406 - 0.533 mm) and can be checked with a caliper. For box style holders
the design clearance between a new brush and the box is from 0.006 to 0.012 inches (0.152 - 0.305
mm) and can be checked with a feeler gauge.

12 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

2. Single Plug-In-Cartridge Style Brush Holder

Figure 10 shows a single brush and brush holder design. The holder consists of a brush holder
cartridge and a support to which the brush holder mounts. The supports are mounted to the brush
rigging support plates. The brush holder can be removed from the supports utilizing an insulated
removable handle.

One separate insulated handle and one brush-changing fixture are furnished for changing
brushes. When not used, the handle should be removed from the brush holder. The brush holder
and brush-changing fixture should be stored in a safe and readily accessible place.

Figure 10. Single Plug-In-Cartridge Style Brush Holder Assembly

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 17

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

The following procedure should be followed to install a new collector brush:

1. Collector brushes shall be replaced when the top of the brush is within 1/8” of the wear
gage; reference Figure 11.

Figure 11. Single Plug-In-Cartridge Style Brush Holder – Brush Wear Gage
2. Insert the handle shaft into the hole / slot in the top of brush holder body until the insulation
of handle seats on the top of the brush holder. Depress (push down) the handle, then turn it
counter-clockwise ¼ turn to lock the handle to the brush holder. The handle will stop
turning when it has reached the ¼ turn position. Reference Figure 12.

CAUTION

While turning the handle, DO NOT FORCE IT. Damage to the handle (especially the
tip), brush holder, or to the support could occur making these parts unusable. If parts are
seated, the handle will engage and turn easily – If excessive resistance is experienced or
the handle will not turn, make sure that the handle is being compressed fully and the
brush holder is seated fully onto the brush changing fixture or support. If it is seated and
will not turn, check the handle (especially the tip), brush holder, and fixture or support
for damage. Repair or replace damaged parts if necessary.

Figure 12. Single Plug-In-Cartridge Style Brush Holder - Brush Holder Handle Installation

18 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

3. Remove the brush holder from the support by pulling on the handle. Slide brush holder
body onto the brush changing fixture (see Figure 13) making sure that the brush holder is
completely seated on the changing fixture. To ensure that the brush holder is completely
seated depress (Push Down) the handle and turn clockwise ¼ turn (handle will stop turning
at ¼ turn position). This will unlock the handle from the brush holder. If the brush holder is
not completely seated it will not be possible to turn the brush handle without excessive
force, see caution notice above.

Figure 13. Single Plug-In-Cartridge Style Brush Holder - Insert Brush Holder into Fixture
4. Insert the brush from the bottom of holder (see Figure 14): A) Squeeze the brush changing
fixtures trigger. B) Insert the brush, lead side first. C) Once the brush is fully in the brush
holder; release the trigger to hold the brush in place. D) Attach the brush terminal to brush
holder body and torque the screw to 4 ft-lb (5 N-m); see Figure 15.

CAUTION

Do not force the brush into the holder. The brush should slide smoothly in the holder. If
the brush does not slide smoothly then the brush holder may not be completely seated on
the brush-changing fixture. Verify that the brush holder is completely seated. If the
brush holder is completely seated and the problem is not resolved then either the brush
holder or the brush-changing fixture is damaged or the wrong brush is being used.
Check all parts and replace as required.

Figure 14. Single Plug-In-Cartridge Style Brush Holder - Brush Installation

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 19
GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

Figure 15. Single Plug-In-Cartridge Style Brush Holder – Proper Shunt Orientation
5. Reinstall the brush handle if it has been removed. Pull the brush holder off of the brush-
changing fixture. The brush spring retainer will engage the brush as it is removed from the
brush holder. This will retain the brush in the brush box until it is installed on the support on
the brush rigging.
6. Grasp the brush holder / brush assembly handle and position the assembly over the support
on the rigging. Slide the brush holder onto the support making sure that the brush holder
fully engages.
7. Ensure that the brush holder seats onto the top of the support and that the brush releases
onto the slip ring. Ensure that the locking pin is extending out of the brush holder as shown
in Figure 16. If it does, the brush holder is properly seated. Remove handle from the brush
holder. If the brush holder is not completely seated it will not be possible to turn the brush
handle without excessive force, see caution above.

Torque mounting
bolts to 12 ft-lbs
[16 N-m]

Figure 16. Single Plug-In-Cartridge Style Brush Holder - Installing the Brush Holder on the Support

20 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

C. Collector Brushes
1. Installing Brushes

Brushes must be replaced when they are within 0.12” of their wear limit. Each brush holder has a
wear limit indicator. Reference section V.B. for the location of the indicator for each brush
holder type.

During normal brush changing, limit the number of brushes installed in a 24-hour period to less
than 25% of the total number of brushes on the individual rings to allow the brushes to wear into
the ring surface. When a full set of brushes is installed on the unit, the field current should be
applied gradually to allow proper seating of the brushes to the rings. It is recommended to
perform the normal daily inspections on the unit after first application of field current on the unit
and at approximately 50 and 100% turbine output base load conditions to verify the brushes are
operating correctly.

2. Number of Brushes

The number of brushes and brush holders depends on the generator field current and the number
of brushes in each brush holder (if applicable). Enough brushes are fitted so that the average
current density in the brush face does not exceed ~65 amperes per square inch (~10 amperes per
square centimeter) during normal operation. Brush current density should not fall below ~40
amperes per square inch (~6 amperes per square centimeter) during normal operation. To meet
these requirements, on some design, not all brush holder locations will be utilized.

3. Brush Contouring

It is good practice to fit the new brushes to the contour of the collector ring. This is best
accomplished on a drum having the same diameter as the ring, and covered with a heavy bonded
production paper such as "garnet.” The fixture to hold the brush relative to the drum must
simulate the same normal position as when the brush is installed in the machine. This ensures
that the brush surface is in proper contact with the ring. Brushes should be sanded in the
direction of rotation only. To be sure that there is no imbedded sand in the brush face, finish by
scraping with a knife. The old brush can be used as a reference when contouring the new brush.

On new installations, or when all of brushes are replaced at one time, the collector rings
themselves can be used as the contouring drum. For this process a sheet of sand paper is placed
around the ring and attached securely in place. The machine is rotated on turning gear, slowly
shaping the brushes to the rings. Extreme caution must be used when doing this. This is best
performed under the supervision of a trained GE service representative. The use of the wrong
sandpaper type, improper installation of the sandpaper, and then the follow-up cleaning
techniques can all have detrimental effects on the machine if not properly performed.

4. Brush Grades

Only the brush grade originally supplied with the collector should be utilized. Brushes of
different grades and different manufactures should NEVER be mixed. Differences in brush
resistance and collector film development can lead to high brush selectivity, increased brush
wear, increased electrical contact losses, overheated brush shunts, and overheated brushes. All of
these conditions can contribute to the onset of a flashover event. If a different brush grade is to
be used, the existing collector ring film should be removed and all brushes should be replaced at
the same time.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 29

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

5. Brush Wear

Brush wear is a function of many variables such as brush temperature, brush material, ring
material, spring pressure, current loading, cooling air temperature, humidity and cleanliness, ring
film, ring polarity, brush to ring contact quality and running speed.

Brush performance is closely related to frictional force between the brushes and rings. Poor
operation may result if the frictional force is either too low or too high.

If this frictional force is too low, the chance of brush bounce and the contact voltage drop
increases. This can result in brush sparking and unbalanced brush current distributions between
brushes. Sparking in turn causes rapid roughening of the collector rings, either in the form of
pitting, threading or grooving, or dark deposits resembling brush marks on the rings. This then
leads to a further increase in brush bounce and sparking. If left unchanged the surface conditions
will continue to deteriorate, and a flashover can occur.

High frictional forces can result in rapid brush wear, brush chattering and possible overheating of
the rings. This chattering may also cause the brushes to chip. The collector rings will have a dark
glossy appearance.

Brush wear will thus obviously vary between generators and for the same generator under
different conditions. That is why daily inspections of the brush rigging are so important. The
average brush life is typically between 2 to 6 months, which corresponds to about 0.5" to 1.5"
inch of wear per 1000 hours of operation. It has often been found that the brushes on the ring of
positive polarity wear more quickly.

D. Clearances
Refer to the generator clearance diagram for proper axial and radial clearances of brush rigging
components. All axial clearances should be verified as part of the first startup, operation and
shutdown sequence to ensure that clearances are maintained over all operational and transient
conditions.

The axial position of the collector brushes has been determined to ensure that they remain fully on the
ring during turning gear operation and during load conditions. Brushes near the edges of the rings
may ride off the ring by up to 1/2 of the brush width during transient conditions such as startup or
shutdown.

It is also important to set the axial position accurately to ensure proper alignment of the collector fan.
Axial-style collector fans should be fully under the fan baffle over the full movement of the rotor.
Radial-style collector fans should be fully under the fan baffle during load conditions. During
transient conditions the radial fan may be either slightly blocked or outside of the fan baffle.

A minimum axial distance of 0.25” shall exist between rotating and stationary components. The seals
between the rotating shaft and the stationary collector shall provide sealing over the full range of
motion.

The axial alignment of the brush rigging can be adjusted in one of several ways depending on the
design. On large steam turbine generators the brush rigging is mounted to a base. The position of this
base can be moved axially to adjust the brush rigging. For all other units the brush rigging is mounted
to threaded rods. These design utilize either a stack of washers that act as shims or the rigging is
positioned between adjustment nuts. For units with washers, the washers must be removed from one

30 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

end of the threaded rod and reinstalled on the other end; see Figure 30. Units with adjustment nuts
can be adjusted by turning the nut along the threaded bar to the desired position; see Figure 31. Some
design with adjustment nuts allow for independent adjustment of both rigging halves. With either
adjustment method, the brush support plate must be kept perpendicular to the collector ring surface.

Figure 30. Collector Brush Rigging Configuration – Washer Shims

Figure 31. Collector Brush Rigging Configuration – Adjustment Nuts

To ensure proper operation a minimum distance of 1.50” shall exist between components of different
electrical potential. This should be verified prior to operation.

Before the brushes are installed, set the brush holders normal to the surface of the collector rings,
with a 0.12” to 0.25" [3.1 mm to 6.4 mm] clearance measured from the ring to the closest portion of
the brush holder. A larger gap does not provide proper support and reduces the usable length and
therefore the life of the brush. Once the location is set, lock the holders / supports in place. Any
adjustments of the brush holders after the brushes are installed will impact the surface contact of the
brush to the collector ring.

The radial alignment is typically adjusted through the use of slotted holes in the brush holder support
plate. On some designs, such as the pin and box style magazine brush holders, radial adjustment is
made on the brush holder itself. In these cases, if a brush holder is removed, it, should be reinstalled
back into its original position. Each brush holder my be set different depending on it’s location to
meet clearance requirements.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 31

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

E. Cleanliness
1. Carbon Dust

Normal brush wear produces a fine, conductive dust, which can deposit on insulating surfaces of
the brush rigging, collector rings / shaft, and housing. Buildup of this conductive dust can result
in a shock hazard even when touching non-electrical parts and can result in a flashover if build-
up of dust becomes severe.

2. Freedom from Oil

It is important to prevent or remove any oil accumulation on the base top, floor or any other
places in the collector enclosure where it may be picked up by an air stream and carried as a
vapor to the collector. Accumulation of oil and carbon dust contributes to lower insulation
resistance readings and impairs the effectiveness of the brush film. There are several common
sources of oil vapor that may contaminate an air stream: leaking joints in an oil-pressure line,
bearing seals, an over-oiled air filter, turning gear leaks and oil that has been centrifuged from
the lubricating grease of a coupling.

3. Ventilation Ducts

Air ducts can become contaminated or blocked with the various materials. A good cleaning is
necessary before startup and at regular maintenance intervals.

4. Filters

Every collector will utilize an inlet filter. These filters are either a pleated paper type filter or a
galvanized steel type air filter. Filter life is dependent on the site-specific environment and use of
the machine. Filters should be checked often to ensure that they do not become clogged.

a. Pleated Paper Air Filters

Pleated paper air filters should be replaced once they become loaded. These filters cannot be
re-used therefore it is recommended that spare filters be kept in stock. Used filters should be
properly discarded.

b. Galvanized Steel Air Filter

A galvanized steel air filter is a high velocity and low-pressure filter designed for industrial
and commercial applications. A galvanized steel screen is utilized to provide the filtration.
The filter has been designed to be cleanable. The filter should be oiled after every cleaning.
The filter should be checked for damage whenever it is removed. Damaged filters should be
either repaired or replaced.

In general, galvanized steel air filters should be cleaned when the pressure drop across the
filter bank increases by ~0.15" W.G. (37 Pa). Typically this would result in a pressure drop
of ~0.25” to ~0.35” W.G measured across the filter bank. This figure may vary from
installation to installation, depending upon the velocities encountered, the type of dust and
dirt being removed from the air stream, and the original design conditions.

32 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

CAUTION

Do not substitute other makes of filters or run without filters while the original
galvanized steel air filter panels are being serviced. At least one full set of spare filters is
recommended so they can be installed while the original filters are being serviced.

Under ordinary conditions, galvanized steel air filters may be readily cleaned with water. A
garden hose with a pressure nozzle and water pressure of 30 to 40 psig [207 to 276 kPa
(gauge)] is satisfactory. Higher pressures are desirable, lower pressure can be used but with
less satisfactory results. Hot water will speed up the cleaning operation. A flat jet nozzle with
hose adaptor is preferable. The stream of water should be directed to the dirty side of the
filter so that the full energy of the water jet will break the dirt mass loose from the media and
surplus water will flush the loosened dirt out through the herringbone-crimped channels. It
may be necessary to front-wash and back-wash filters with heavy dirt loads.

When dirt loads are heavy or tenacious, or where a considerable number of filters are
involved or when a faster cleaning operation is required, the filters should be presoaked in an
alkaline cleaning solution. Recommendation of the exact material to use and instructions for
its use should be obtained from the manufacturers of cleaning products. Typically dry
compound alkaline cleaners such as Turco No. 16, Oakite Penetrant, and Kelite Super S. are
sufficient and inexpensive. More expensive, specially prepared dry compounds, such as
Oakite No. 24, Turco Type X or Kelite Formula 953 have advantages for removing
particularly tenacious dirt. Prepared alkaline solvents are more expensive than dry
compounds, and usually cannot be justified except for removing contaminants having a large
percentage of tenacious, greasy substances. Typical materials of this sort are Kelite KDL-28,
Turco Slip and Oakite No. 99. Air filter maintenance organizations using Automatic or
Manual Air Filter Cleaning Equipment often can do a better job more economically than the
user. Check with your manufacturer's representative for the name of a reputable service
company in your area.

After the filters have been washed and rinsed they should be drained until substantially dry
before they are oiled. Any good grade commercial lubricating motor oil can be used.
Odorless oils with a flashpoint above 350ºF (177ºC) are recommended. Reference Table 3
for recommended oil viscosities.

Table 3. Recommended Viscosity Grades for Galvanized Steel Air Filter

SAE Viscosity Recommended Operating Range
60 75ºF (24ºC) to 130ºF (54ºC)
30 40ºF (4ºC) to 75ºF (24ºC)
10W Below 40ºF (4ºC)

To oil the filters, either completely immerse the filter in oil until air bubbles stop or spray
both sides with oil. The immersion method is preferred as there is less chance for improper
oil application. Stand the filter on edge with the drain holes down for 12 to 24 hours. The
filters should be drained in an ambient environment of at least 70ºF and 10ºF above the
maximum operating temperature to prevent oil from dripping from the filters after they are
reinstalled. Ensure that the filter is not over oiled; this may lead to collector ring
contamination.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 33

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

5. How to Properly Clean the Collector

The following recommendations should be followed to properly clean the collector.

a. The collector brushes should be removed when cleaning the collector.

b. To clean the collector components, start with a vacuum (with a fine particle filter) and a clean
dry rag. A bottle brush and compressed air can be used to clean the cooling passages of
ventilated collector rings. Use of compressed air should be kept to a minimum as this may
force conductive particles into small crevasses that are difficult to clean.

c. A rag that has been dampened, not saturated, with either contact cleaner, or, if not available,
denatured alcohol, can be used to clean all surfaces including the collector ring brush-riding
surface. This will not remove the collector ring brush-riding surface film. The use of a
contact cleaner or denatured alcohol can result in low insulation resistance readings until the
water content evaporates.

d. In addition to rags, scotch brite pads may be used on all surfaces except the collector ring
brush-riding surface. Never use scotch brite pads on the collector ring brush-riding surface,
this will impede the build-up of the surface film.

e. If required, the collector ring film can be removed utilizing a canvas wiper. In general, the
collector ring film should not be removed; it is needed for proper operation of the collector
brushes.

f. If oxidation is found on electrical contact surfaces, it may be removed by a very light

application of sandpaper. If the plating is removed, the part should be replaced.

F. Collector Ring and Brush Vibration

Excessive collector vibration can result in brush bounce, arcing and ultimately a flashover. Unless a
very light, brush mounted accelerometer or similar method is utilized it is not possible to achieve
accurate collector brush vibration readings because of the weight of the measuring device and the
contact force between the device and the brush. As a result, collector ring surface vibration
measurements are typically collected. Assuming brush bounce is not present, the collector ring
surface vibration measurements will be identical to the brush vibration. If the brush is not remaining
in contact with the ring, these two measurements will differ in amplitude and/or frequency.

Collector ring surface vibration measurements can be obtained by mounting a vibration detector
(accelerometer, etc.) on top of an insulated rod and carefully placing the rod in contact with the top
surface of a brush. Applying firm pressure to the brush will provide a reading of the collector ring
surface vibration. Applying light pressure will provide a means to determine brush vibration directly
however it must be understood that these readings are most likely a compromised measurement
because of the weight of the measuring device and the contact force between the device and the brush

It is important to monitor brush vibration magnitude and dominant frequencies on several specific
brushes. It is recommended that a plot of vibration magnitude of selected brushes, measured weekly,
be made against time, as indicated in Figure 32. Assuming unchanged generator balance, brush
vibration can be expected to increase slowly over a long period of time due to collector ring wear.
The collector rings will wear slowly, generally into a series of peaks and valleys around the periphery
and varying between the different brush tracks. If brush vibration is allowed to increase excessively, a
point in time will be reached when the brushes are no longer able to maintain proper ring contact

34 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

around the entire periphery. When all brushes simultaneously loose contact with the collector ring the
current will flow between the brushes and the ring through arcs. The arcing will escalate erosion of
the ring surface and will very quickly deepen existing valleys. This will cause increased brush
vibration and associated ring erosion. This “runaway” condition will increase much more quickly
with time and will result in brush damage or sparking, collector ring pitting, and ultimately a
flashover, if not corrected.

Brushes May
Brush Vibration Start Bouncing
Mills P-P

Time in Months

Figure 32. Long Term Brush Vibration

There is no single value of brush vibration magnitude that signals the start of brush bounce; instead
brush acceleration is a much better indicator. Historically, brush accelerations above 0.8 g's rms are
considered to be marginal and trouble is imminent above 2 g's rms. The curves in Figure 33 express
the variation of the vibration magnitude guidelines as a function of the vibration frequency. For
example, for 3000-rpm collector systems, 1 per rev brush vibration magnitudes of less than 0.009”
peak to peak (0.229 mm) will result in acceptable performance.

Figure 33. Acceptable Vibration Levels for Generator Collectors

At the lower operating speeds, the ability of the collector to operate reliably will not be determined as
much by brush acceleration; instead, other mechanisms related to the magnitude of vibration can
result in long-term deterioration of the carbon brush collector system. For this reason, the region of
acceptable vibration magnitude is limited to 0.010” (0.254 mm) as shown in the curve. Past
experience has shown that the objective of maintaining low vibration levels has contributed to an
excellent collector reliability record. In-service maintenance programs should continue to work to
that objective as depicted by staying within the “acceptable” region of the curve. It is important to
recognize that these curves represent guidelines and that careful inspection of the brushes and
tracking of vibration magnitudes is important, particularly if the vibration levels are in the regions
designated as “marginal” or “trouble may be imminent”.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 35
GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

G. Insulation Electrical Testing

To ensure proper electrical operation all parts shall be free of contaminates (chips, dirt, water, etc.).
Prior to the initial startup and after extended outages, especially those involving collector
maintenance, the following test shall be performed to ensure an adequate and clean insulation system
exists. Testing shall be performed at ambient temperatures. The brush rigging base shall be grounded
during these tests; reference Figure 34.

Figure 34. Typical Brush Rigging Electrical Test Setup

All applicable safety precautions (governmental, shop, etc…) shall be taken to ensure a safe test.
During testing, at a minimum, the equipment shall be roped off to avoid inadvertent contact.
Immediately after any test the power source shall be powered down and disconnected and a ground
shall be applied prior to coming in contact with the tested components.

Perform a pre-high-potential insulation resistance test between the inboard brush support and ground
with the outboard brush support grounded. Perform a similar test between the outboard brush support
and ground with the inboard brush support grounded. The test voltage shall be 500VDC. The 1
minute resistance reading shall be 20 megohms or greater.

Perform a high-potential test between the inboard brush support and ground with the outboard brush
support grounded. Perform a similar test between the outboard brush support and ground with the
inboard brush support grounded. Apply a test voltage of 2800VAC (3200VAC for initial startup
only) 50Hz or 60Hz for 1 minute. Alternate test voltage of 4800VDC (5400VDC for initial startup
only) may be used if the 2800VAC (3200VAC) is not available. This test voltage is based on IEEE
421.3-1997 and a maximum exciter rated output of 750VDC.

Perform a post-high-potential insulation resistance test between the inboard brush support and ground
with the outboard brush support grounded. Perform a similar test between the outboard brush support
and ground with the inboard brush support grounded. The test voltage shall be 500VDC. The 1
minute resistance reading shall be 20 megohms or greater and at least 60% of the pre high potential
insulation resistance test.

If these values are not reached then disassembly and further cleaning is likely needed. A visual
inspection for damaged or cracked insulating components should also be performed as this would
also result in low values. Refer to the General Electric Company if the source of the low values
cannot be fixed or identified.

H. Collector Hardware
All parts of the brush rigging must be kept tight. At each shutdown, check all nuts, bolts and screws
for tightness. This is particularly important, since the insulating components have a slight tendency to
shrink, which relieves the bolting pressure. If not corrected periodically, excessive vibration of the
brush holder rigging may take place. Ensure that bolts do not bottom out. Prior to startup ensure that
all lock tabs are correctly bent and all dowels have been installed.

36 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

VI. MAINTENANCE INSPECTION SCHEDULE

A planned collector maintenance schedule should be followed for each generator. At a minimum, the
following recommended maintenance schedule should be followed. These recommendations should be
adjusted to fit site specific needs.

A. Recomended Spare Parts

At a minimum it is recomended that the following parts be kept on hand.

a. Collector Brushes (Minimum 1 Set)

b. Spare Brush Holders (2 Minimum)

c. Collector Filters (1 Set)

d. Brush Holder Handle (1 Minimum) – If not intergral with the brush holder; refer to section V.B.

e. Brush-Changing Fixture (1 Minimum) – If required for changing brushes; refer to section V.B.

B. Daily Inspection
Perform daily inspections through the housing windows or by removing / opening the collector house
doors.

Look for the following:

1. Check for brush sparking. Sparking at the ring surface may usually be corrected by wiping the
rings with a heavy canvas pad mounted on a board. If sparking occurs on only one brush, it may
sometimes be corrected by applying extra pressure to that brush for a moment. If this is not
successful, remove the brush holder and brush, and inspect all parts carefully for damage, wear,
or foreign material.

2. Replace any broken brushes and brushes that are within 0.12” of their wear limit. It is normal for
the positive brushes to wear at a greater rate than the negative brushes.

CAUTION

Brushes must be replaced when they are within 0.12” of their wear limit.
Any attempt to use the brush beyond this point may result in contact between the pigtail
and the brush box and loss of contact between the brush and the ring. This could lead to
serious damage of the collector and brush rigging assembly and must be avoided.
Replace the worn brushes as required to prevent this situation.

3. Look for brushes that have tight / over extended shunts or that are otherwise hung up.

4. Check for overheating.

5. Check for dust or oil accumulation.

6. Check for chattering of brushes and springs

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GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

7. Check for loose, frayed, blued, or burned brush pigtails

8. Check for broken or loose hardware, replace or tighten as required.

9. Check for any noticeable change in collector ring film conditions.

10. Look for any significant changes from previous conditions.

11. Check for any noticeable increase in noise level or changes from the previous inspection.

12. From the control room, if provided, monitor the generator field temperature, voltage and collector
air temperature rise under similar load conditions for changes. Erratic and generally higher
indicated field temperature readings could be an indication of possible collector arcing.

C. Weekly Inspection
In combination with the typical daily inspections, at least once a week, remove / open the collector
house doors to provide full access to the brush rigging to perform the inspections listed below.

NOTE
Remove the collector house doors on a more frequent basis if conditions require it,
such as poor visibility or history of rapid brush wear.

1. Record the vibration level on a few specific brushes on each ring. Plot on a long-term vibration
chart to determine trends and/or changes. Also check for an increase in the vibration level on the
brush holder rigging. Vibration above recommended limits (see section IV.V.F. ) should be
corrected.

2. Remove all brush holders, one at a time, and inspect. Examine brushes for pitting, edge chipping,
grooving or threading. Examine the constant-pressure springs for cracks or loose rivets. Examine
the brush holders for damage and carbon buildup. Inspect the brushes in the brush holder to
ensure the brushes are not hung up in the holder. If uncertain, remove one brush at a time and
inspect then reinstall. For example, dust accumulation around the gap between the brush and the
brush holder can cause the brushes to hang up.

3. Inspect the ductwork and air filters to ensure they are not obstructed.

D. Monthly Inspection
With the following additions, monthly inspections are otherwise the same as weekly inspections. The
purpose of these additions is to cross-check for any signs of wear that may have escaped detection
and to provide a written running record of brush and ring wear, vibration amplitude and general
overall performance. If rings are wearing or vibration is building up, this should be recorded. A
review of this record as a scheduled outage or period of overhaul approaches may give a good
indication of what servicing, if any, is required.

1. Look closely at the rings under a strobe light for signs of either markings or wear not otherwise
visible.

2. Plot the vibration magnitude of the brushes measured on a long-term vibration graph and note
changes in trends.

38 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

3. If the measured brushes operate at high vibration levels, a vibration measurement of all brushes
may be warranted. This will give an idea of whether the problem is confined to one ring or to
specific brush tracks.

4. Utilize thermography to look for hot spots.

E. Inspections and Servicing During Shutdowns

Prior to an extended shutdown, review and analyze the operating data that has been periodically
recorded for any signs of concern such as brush vibration levels, ring visual inspections, etc. This will
give some insight as to what maintenance work should be scheduled for the outage and what new
parts or necessary equipment will be needed. This particularly applies to allowing the time and
obtaining the equipment for grinding collector rings, if necessary. After shutdown, recommended
procedures are as follows:

1. Remove the collector brushes if the unit will be shut down for extended periods (greater than one
week), to avoid electrolytic pitting of the rings.

2. With the unit on turning gear, indicate each brush track and record the runout pattern. If rings
have been ground at speed, they may not be round but elliptical to suit the vibration pattern of the
machine. Part of the traverse indication will be unusable as read because of the interference of the
grooving, which allows the indicator button to give a false reading. Taking the reading on the
brush is often used to prevent this. If the ring runouts exceed limits (see Sections IV., V.A. and
V.A. 3. ), then resurface by grinding (see section VII).

3. Replace any worn or damaged components.

4. Measure the spring force of the constant pressure springs, if they are not within specifications
they should be replaced.

5. Ensure that all brush-rigging bolts are tight.

6. Remove any dirt or carbon dust from fan guards, blades and ring and rigging. Clean the collector,
reference section IV., V.E. .

7. When the collector rings are resurfaced, the diameters of the rings should be checked. Ring wear
is inherently different for the two polarities. If collector ring wear differs significantly, consider
reversing the polarity of the rings to improve ring life. Note that there are other reasons for
uneven ring wear such as contamination or arcing that should be ruled out prior to switching the
polarity

8. Perform brush rigging electrical testing, reference section V.G. .

9. Before restarting the machine, inspect for proper clearance.

10. If the rings are resurfaced during the outage, establish a new carbon brush film before applying
full current to the brush rigging.

11. Ensure that all actions associated with applicable TILs are completed.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 39

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

VII. RESURFACING COLLECTOR RINGS

A. General
Steel collector rings must be resurfaced periodically to reduce brush vibration and thus prevent rapid
deterioration of the brushes. Most brush wear patterns in collector rings can be classified into two
types:

1. A groove that reduces the ring diameter on the brush tracks but leaves the ring round.

If the rings remain round, the grooving will not affect operation until the wear grooves are worn
deep enough to shear brushes when axial ring movements due to rotor expansion or contractions
occur.

2. A wearing that changes the original roundness of the ring to an irregular contour of high
spots and valleys. This type of wear has a detrimental effect on brush operation.

If the rings develop an irregular contour around the periphery, a few mils of wear may be
sufficient to start brushes chipping or crumbling at the edges. The frequency of diameter change
rather than the amount of change results in a high rate of radial acceleration, and, consequently,
produces damaging brush impacts. A few mils of change in diameter occurring in 5 degrees of
rotation can be more damaging than a much larger change occurring in 360 degrees.

If vibration has been severe, do not reapply any of the brushes. Even though some may have
considerable usable length, they have been subjected to vibration fatigue, are probably worn in width
and thickness, and possibly have been excessively heated so that their binder is damaged. Install a set
of new brushes.

Prior to the time when rings are to be ground, give rings, brushes and pines a thorough inspection,
preferably with a strobe light. Determine the clearances between the brush holder and the new brush,
and, if needed, replace the brush holder. Prior to grinding, thoroughly inspect the rings, brushes and
boxes. Determine the brush holder to brush clearances using a new brush. Do not continue to use
brush holders that are worn oversize or that have worn springs.

B. Resurfacing Guidelines

CAUTION

Should resurfacing of rings become necessary, it is strongly recommended that it is done

by a GE approved service shop experienced in servicing collector rings.

The following basic procedure should be followed to resurface collector rings.

1. Determine the brush vibration pattern.

Unless the vibration pattern is known from previous experience, record each brush amplitude
with a wooden stick and a vibration indicator to determine whether readings are fairly constant
or whether they have a variation from high to low in the form of an elliptical pattern. For the
latter, it is best to take the readings more than once and plot the results on polar coordinate paper
to establish the major and minor axes of vibration pattern.

40 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

2. Measure shaft vibration.

Measure the amplitude of shaft vibration near the collector rings by means of a stick and
vibration indicator. Predominant vibration frequencies of once-per-revolution suggest shaft
unbalance; higher frequencies suggest several peaks and valleys in the ring surface. If this
vibration is excessive, a balance refinement may be required before rings are ground.

3. Estimate the depth of the wear grooves and machine the rings (if required).

If the depth of the wear grooves appears to be over 15 mils (0.381 mm), remove the grooves by
preliminary resurfacing the ring with the unit on turning gear before grinding. If the wear is less
than 15 mils (0.381 mm), the preliminary resurfacing operation may be omitted.

The preliminary resurfacing can be done with a coarse grinding stone or with steel tool bits held
in a lathe compound. If tool bits are used, they should preferably be made of high-speed tool
steel, ground to minimize chatter and depth of tool marks. Collector rings with axial cooling
holes are generally heat treated to a hardness of between 280 and 320 Brinnell. Other rings have
a Brinnell hardness somewhat lower (230 to 270). The resurfacing tooling used should be in
excellent condition to obtain the proper surface finishes required. Maximum rigidity should be
built into the tooling, which supports the crosshead from the exciter base or from the floor.
Preliminary resurfacing at low speed should be continued until the original wear marks are
almost completely removed.

4. Grind the collector rings.

There are two basic methods of grinding collector rings: (1) on turning gear and (2) at rated
speed.

When grinding on turning gear, the objective is to get the collector ring round, and with good
shaft balance; this is how the ring will essentially appear to the brushes at speed. Grinding at
turning gear requires the use of a grinding wheel or a belt sander; see Figure 35. Precautions
have to be taken prior to grinding on turning gear, to ensure that the shaft is turning smoothly in
its bearings, that the collector shaft extension is not unduly flexible, and that turning gear
operation is not jerky. These things have to be checked out, especially on some older units, since
their existence may not give any choice but to grind at speed.

Figure 35. Grinding on Turning Gear using as Grinding Wheel (left) and Beltsander (right)

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 41

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

When grinding at rated speed with stationary grinding stones, the objective is to compensate for
shaft vibration to make the ring appear “round” at speed; in other words, “grind out” the
vibration. Later changes in rotor balance will also change the effective ring contour. If ground at
speed, line up the grinding stone with the major axis of vibrations. Note that if the rings were
ground at speed, the runout of the rings as measured with a dial indicator at slow speed may be
several thousands of an inch. Do not attempt to improve this, as the important thing is to
maintain minimum brush vibration at rated speed regardless of its value at low speed.

If properly done, either method will accomplish the objective of giving the brushes a continuous
and polished surface on which to ride. While grinding at speed will provide a smoother running
surface this option is typically not practical.

Mixing the two methods is generally not recommended. There is a danger in doing most of the
metal removal on turning gear and then finishing at speed. Because the ring contour looks
differently at speed since it reflects shaft vibration, the finishing stone does not necessarily touch
the entire ring periphery but only the high spot or spots. The ring may thus end up with an
irregular contour. Therefore, if only the finishing is done at speed, it is imperative that enough
metal is removed to completely grind out the shaft vibration pattern.

Grinding at intermediate speeds is definitely not recommended. One reason for this is the
generator shaft usually has critical speeds below running speed and the shaft vibration pattern
characteristic to that particular intermediate speed would be ground out, possibly resulting in a
rather non-uniform ring periphery at rated speed. Furthermore, prolonged running at intermediate
speeds may damage some turbine components.

When grinding the collector ring gradually reducing the amount of metal removal with each
action until the appropriate surface finish is obtained. Note the cutting action under the
stroboscopic light and continue grinding until all irregularities have nearly been removed. Then
switch successively to the medium, finish, and polish tooling. Do not use crocus cloth during the
resurfacing operation. Check vibration, at speed, with an accurate vibration-measuring device
held on a stick with a carbon brush at the end riding on the ring. If no elliptical vibration is
present, brush vibration should not be greatly different than shaft vibration.

Whatever method is chosen, there are two factors of utmost importance: (1) The ring surface
finish should approach eight micro-inches. (2) The ring surface contour should be smooth
without sharp peaks and valleys that result in high brush acceleration and possible brush bounce.
At speed, brush vibration, should be the same as collector ring surface vibration. Vibration
amplitudes of 0.002” [0.051 mm] is fairly common, some rings have been ground to less than
0.001” [0.025 mm].

5. Remove the metal slivers and feather the edges from the spiral groove.

Metal slivers will cause rapid brush wear. Remove the metal slivers and feather edges at turning
gear speed; this cannot be done at speed with a small hand stone.

6. Clean the rings after machining is finished.

The rings should be free from markings, rust, dirt and oil. Oil and dirt can be removed with
petroleum spirits, after which additional cleaning must be accomplished by an application of
alcohol followed by a dry cloth to remove any remaining moisture. The cleaning must be done
with care to prevent liquid from dripping on to insulation parts. Avoid handprints or fingerprints

42 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 Collector and Carbon Brush Rigging Installation, Operation and Maintenance GEK 116362a

on the rings, because the body moisture left by such an imprint will cause rust. If any nicks or
small upsets in the surfaces on which brushes bear have occurred during handling, blend them
smooth with a hand stone

C. Required Equipment
Depending on the method to be used for resurfacing the required equipment will vary. The typical
tools that are required are dial indicators, micrometers (large enough to measure the ring OD),
vibration indicators, cutting stones and tools, small crosshead or lathe and a carbon brush attached to
an electrically insulated handle to be used to gather vibration readings by applying an accelerometer
to the top of the brush.

The specific cutting stones recommended are made by Ideal Industries in Sycamore, Illinois
(www.idealindustries.com). These are made in the following five different degrees of coarseness:

● 80–454X (Extra Coarse)

● 80–45-4C (Coarse)
● 80–454M (Medium)
● 80–454F (Finish)
● 80–454P (Polish)
The X is rarely used if rings have been turned, but at least three of each of the others (total of 12)
should be on hand. The 80-series stones wear away at a rate sufficiently fast so that their cutting face
does not become loaded with metal. Store the stones in a dry place. If the stones are damp, they wear
away too fast

The rigging to support the crosshead should be ready before the machine is taken out of service. It
should provide a firm, rigid support to the base or foundation. A recommended crosshead is the
Midget, made by Ideal Industries in Sycamore, Illinois (www.idealindustries.com).

VIII. TECHNICAL SUPPORT

In case of difficulty with the brush rigging or collector rings, which cannot be corrected by reference to
these instructions, it will help if the following information is submitted to the General Electric Company:

1. Complete description of the specific trouble and generator serial number.

2. Grade and number of brush being used.
3. Average excitation current on the generator.
4. Unusual atmospheric conditions, including temperature, humidity, and contaminants.
5. If the difficulty is associated with one polarity, state which, as determined by a voltmeter.
6. Approximate brush vibration and shaft vibration at the adjacent bearing.
7. Average brush life being obtained on each polarity.
8. Date rings were last resurfaced and method used.
9. History of any other maintenance activities performed on the collector assembly.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 43

GEK 116362a Collector and Carbon Brush Rigging Installation, Operation and Maintenance

g GE Energy
General Electric Company
www.gepower.com

44 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

DWG Number 229D1756 Rev A Released 8/26/2013 Page 6 of 11

SHEETS 6, 7,8, AND 9 OF

THIS DOCUMENT WERE
EXTRACTED FOR
OPERATIONS TRAINING
PURPOSES. 2014

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DWG Number 229D1756 Rev A Released 8/26/2013 Page 7 of 11

GE Proprietary Information - Class II (Internal) US EAR - NLR

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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 229D1756 Rev A Released 8/26/2013 Page 9 of 11

GE Proprietary Information - Class II (Internal) US EAR - NLR

Tab 22
DWG Number 145E4602 Rev A Released 2/19/2013 Page 1 of 4

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GE Proprietary Information - Class II (Internal) US EAR - NLR
 e
Shaft-Sealing System for Hydrogen Cooled Generator
(Typical)

BEARING HOUSING

FEED TO SHAFT SEALS

TURBINE END COLLECTOR END

SCAVENGING LINE
BEARING DRAIN
SEAL DRAIN ENLARGEMENT

GENERATOR CASING

HIGH OIL–LEVER ALARM

BAFFLE

SCREEN

SIGHT GLASS
BEARING DRAIN GENERATOR GAS–
ENLARGEMENT
PRESSURE
SENSING LINE

DIFFERENTIAL
PRESSURE GAGE

DIFFERENTIAL PRESSURE
SWITCH FOR STARTING
EMERGENCY SEAL
OIL PUMP
SEAL OIL–PRESSURE
SIGHT
GLASS SENSING LINE

LOW DIFFERENTIAL
PRESSURE ALARM
SWITCH

LOOP SEAL

FILTERS
PRESSURE
FLOAT TRAP REGULATOR FLOW METER

TURBINE
OIL TANK

STF11–14
g
GEK 116742
October 2010

GE Energy

Shaft Sealing System

Hydrogen-Cooled Generators: Scavenging

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 116742 Shaft Sealing System

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Shaft Sealing System GEK 116742

TABLE OF CONTENTS

I. PURPOSE ....................................................................................................................................... 4

II. DESIGN FEATURES (REFERENCE THE TURBINE-GENERATOR P&ID) ..................... 4

A. Shaft Seal ................................................................................................................................. 4
B. Seal Oil Control........................................................................................................................ 4
C. Oil Filter ................................................................................................................................... 4
D. Differential Pressure Regulator................................................................................................ 4
E. Instrumentation ........................................................................................................................ 5
F. Seal Drain Enlargement and Float Trap ................................................................................... 5
G. Bearing Drain Enlargement...................................................................................................... 6

III. III. OPERATION (SEE THE TURBINE-GENERATOR P&ID) ............................................. 6

A. General ..................................................................................................................................... 6
B. Checking the High Oil Level Alarm ........................................................................................ 6
C. Putting the Shaft Seals (H2 Seals) in Operation ...................................................................... 7
D. Charging the Casing with Air (Also Reference Gas Control Valve Operation Diagram)........ 7
E. Adjustment of the Pressure Regulator...................................................................................... 8
F. Adjustment of the Seal Oil Pressure Switches......................................................................... 8
G. Shaft Seal Oil Flow Check....................................................................................................... 9
H. Float Trap Vent Line ................................................................................................................ 9
I. Operation at Reduced Gas Pressures........................................................................................ 9
J. Oil Filter Transfer..................................................................................................................... 10
K. Oil Filter Cartridge Replacement ............................................................................................ 10

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 116742 Shaft Sealing System

I. PURPOSE

To safely and effectively employ hydrogen for generator cooling, it is necessary to contain the gas in the
generator casing. Therefore, shaft seals are required at each end of the generator where the rotor extends
through the end shield. A radial oil film type seal is used for this purpose.

II. DESIGN FEATURES (REFERENCE THE TURBINE-GENERATOR P&ID)

A. Shaft Seal

The shaft seal at each end of the generator consists of a two-piece hydrogen seal casing containing a
pair of babbitted steel rings. Each ring is made up of two 180-degree segments to facilitate assembly
of the seal rings into the hydrogen seal casing. The ring segments are assembled against the side walls
of the seal casings using garter springs, and are held concentric with the shaft by the hydraulic pressure
of the seal oil. The rings, which have a bore diameter only a few mils greater than the shaft journal, are
free to float radially but are prevented from rotating with the shaft by a stop in the upper half of each seal
casing. Oil from the seal oil control system at a pressure of about 5.5 psi (37.9 kPa) above the hydrogen
pressure in the generator is supplied to the seal casing. The oil then passes radially through the space
between the rings and axially along the shaft between the shaft and seal rings in both directions. It is
this thin film of oil between the shaft surface and the rings that actually seals the hydrogen within the
casing.

The total oil flow to the inner- or hydrogen-side rings of the two shaft seals is nominally in the range of
two gallons (7.57 liters) per minute, while the flow from the outer- or air-side rings is several times that
amount. A large air-side flow is needed to cool the rings while a low hydrogen-side flow is essential
for satisfactory operation of the continuous scavenging system.

B. Seal Oil Control

Pressurized oil for the seals is supplied from the main lubrication system to the seal oil controls where
it is regulated to maintain the 5.5 psi (37.9 kPa) differential. The quantity of the total seal oil flow can
be read directly from the flow meter.

C. Oil Filter

Depending upon the application, some seal oil systems have oil filters to filter the oil before it is fed
to the seals. The oil filter is a duplex type with a transfer valve. One filter housing is in operation at a
time. By means of the transfer valve the operation can be switched to the other housing while the first
is serviced. The procedure is reversed when the second housing needs service. The filter elements are
resin treated pleated paper and should be replaced before the differential pressure reaches 6 psid (41.4
kPa). An alarm for high differential pressure across the filter is set at 8 psid (55.2 kPa).

D. Differential Pressure Regulator

A pilot-operated differential pressure regulator is provided for controlling the seal oil pressure at the
shaft seal. The pilot-operated valve uses inlet pressure as the operating medium, which is reduced
through pilot operation to load the actuator diaphragm. Outlet or downstream pressure opposes load-
ing pressure in the actuator and also opposes the pilot control spring. The pilot-operated regulator is
designed to maintain a constant differential pressure across the hydrogen seals.

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Shaft Sealing System GEK 116742

The upper connection of the pilot valve diaphragm is piped to the seal drain enlargement and senses the
gas pressure in the generator casing. The lower connection of the pilot valve diaphragm is piped to one
of the two lower connections of the regulator diaphragm. The other lower connection of the regulator
diaphragm is piped to the seal oil supply line and senses oil pressure being supplied to the shaft seals.
When the outlet pressure drops below the setting of the pilot control spring, pilot control spring force in
turn opens the pilot valve plug, providing additional loading pressure to the actuator diaphragm. This
loading pressure tends to open the main body valve thus supplying the required flow downstream to
the seals. When the downstream pressure is satisfied the outlet pressure tends to increase which in turn
acts on the pilot and actuator diaphragms. This pressure exceeds the pilot control spring setting, thus
letting the valve plug spring close the pilot valve plug. Reduced actuator loading pressure permits the
main valve to close. Once adjusted, the regulator will maintain a nearly constant 5.5 psi (37.9 kPa)
pressure differential between the seal oil and the generator hydrogen through the complete range of
hydrogen pressures.

E. Instrumentation

An instrument panel contains a differential pressure gauge and three differential pressure switches.
These instruments sense seal oil pressure at the seals with respect to gas pressure. Two switches activate
on low-low seal oil differential pressure, to start the dc emergency seal oil pump located on the lube
oil tank. A switch also activates and sends an alarm to the control system on low seal oil differential
pressure. Pressure gauges are provided to measure seal oil pressure upstream of the differential pressure
regulator, at the turbine end seal oil feed line, and at the collector end seal oil feed line. A flow meter
provides indication of total seal oil supply to the seals. Valving is provided for adjusting, testing and
draining all instruments.

Differential pressure instruments, measuring gas pressure versus seal oil pressure, must be recalibrated
in the field due to static oil head in gas pressure sensing lines from seal oil enlargement to skid. Instru-
ments should read seal oil differential pressure as would be read at the generator seals.

F. Seal Drain Enlargement and Float Trap

A hydrogen detraining tank (seal drain enlargement), is provided for removing entrained hydrogen gas
from the hydrogen side seal ring oil discharge. The seal drain enlargement (SDE) may be configured
as two smaller tanks, or as one tank with an internal baffle. The seal drain enlargement(s) is located
below the generator casing and above the level of the air detraining tank (bearing drain enlargement).
In either seal drain arrangement, both the CE and TE discharge are drained through a common line to
a float trap. The float trap, which is required to prevent the loss of hydrogen with the drain oil when
operating at elevated hydrogen pressures, drains to the bearing drain enlargement (BDE) where further
detraining takes place before the oil returns to the main lubricating oil tank. The float trap assembly
is separate from the seal oil control unit and is mounted in close proximity to the generator at a level
below the seal drain enlargement.

Piping from the top of the CE and TE seal drain enlargement(s) connects to control valving and a
flowmeter in the hydrogen control cabinet. The lines are equipped with oil traps to prevent oil from
filling the hydrogen control panel in the event of an abnormally high oil level in the seal drain enlarge-
ment. This arrangement permits a small amount of hydrogen to be continuously discharged to atmos-
phere from each seal drain enlargement. This discharge of hydrogen causes a small flow of hydrogen
past the inner oil deflector of the generator hydrogen seal casing. This flow prevents air liberated from
the hydrogen side seal oil, as it passes through the drain chamber of the seal casing, from passing into
the generator casing. Since this scavenged hydrogen must be continually replaced with pure hydrogen,
the purity of the gas in the generator casing is maintained at a high value.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

GEK 116742 Shaft Sealing System

Another vertical pipe - open at the top - is located inside one of the seal drain enlargements to collect
the oil which results from an abnormally high oil level in the enlargement. This overflow is piped to a
liquid detector with an alarm switch. Since the TE and CE enlargements are connected either internally
or by a common drain line, a high level in either will result in the operation of the alarm. An abnormally
high oil level is usually caused by incorrect operation of the drain valves or float trap.

G. Bearing Drain Enlargement

The air-side seal oil, the generator bearing oil, and the hydrogen-side seal oil (after passing through the
seal drain enlargement and float trap) drain to a chamber mounted on the generator casing (bearing drain
enlargement). The bearing drain enlargement (BDE), provides a large surface area for defoaming and
detraining the oil before it is returned through a loop seal to the main lubricating oil tank. Hydrogen that
is in solution within the oil will also be released due to the drop to atmospheric and vent to atmosphere
by way of a customer connection mounted to the top of the bearing drain enlargement.

In the event of failure of the shaft seal oil supply, hydrogen will pass from the generator into the bearing
drain enlargement and be vented to the atmosphere. The oil loop seal provides a barrier to prevent the
hydrogen from entering the main lubricating oil tank.

III. III. OPERATION (SEE THE TURBINE-GENERATOR P&ID)

A. General

1. Whether the generator is running with air or hydrogen, it is necessary at all times to have the shaft
seals in operation.

2. When running with air, shaft sealing is necessary in order to supply oil to the seal rings to prevent
their heating up and seizing the shaft (due to small diametral clearance between seal rings and the
shaft).

3. When running with hydrogen, shaft sealing is necessary in order to confine the hydrogen in the
generator casing.

B. Checking the High Oil Level Alarm

The high oil level alarm switch actuates an alarm when there is an abnormal rise in the oil level in the
seal drain enlargement.

To test the operation of this switch, first close the isolation valve then remove the fill pipe cap and pour
in water. This should cause the float in the switch to rise and close the alarm contacts. After testing,
drain the water by removing the drainpipe cap. Replace both pipe caps and open isolation valve.

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Shaft Sealing System GEK 116742

C. Putting the Shaft Seals (H2 Seals) in Operation

The shaft seals may be put into operation, and adjustments made to the seal oil components, any time
after the lubrication system and seal oil system have been completely flushed and are ready for oper-
ation. Adjustments to the seal oil system must only be made when seal oil is being properly supplied
from the main lubrication system.

When putting the shaft seals in operation the following steps should be followed:

1. Isolate all sensing and flow valves to differential pressure regulator (No pressure in the downstream
line).

2. Fully open the downstream sensing and flow valves.

3. Open upstream flow valve just enough to hear flow start running through regulator valve.

4. Once flow can be read on the flow meter slowly open the upstream flow valve to the fully open
position.

5. When the valve is regulating steadily, slowly open the upstream sensing valve to the fully open
position.

Oil from the main lubrication system is supplied through the pressure regulator and flow meter to the
shaft seals. Following the steps listed above will ensure sudden pressure changes will not damage the
diaphragm of the pilot valve and/or pressure regulator. The main valve diaphragm is designed for a
maximum differential pressure of 100 - 125 psid (689.5 - 861.8 kPa), and care should be taken never
to exceed this value. All other valves on the seal oil control system should be open or closed as shown
on the P&ID for normal operation. Check to make sure that seal oil is flowing to the seals. This will
be indicated by the flow meter.

D. Charging the Casing with Air (Also Reference Gas Control Valve Operation Diagram)

Adjustments of the seal oil control components should be made with the hydrogen supply disconnected
and air pressure in the generator casing. Start the seal oil pump. Remove the pipe plug from the air
test/purge connection located in the purging control valves assembly and admit dry air to the casing
through this connection. Adjust the valves to charge the casing with 15 psi (103.4 kPa) of air as read on
the casing pressure gauge on the hydrogen manifold and/or the hydrogen control panel pressure gauge.

NOTE

Gas in the differential pressure regulator or the pilot lines will create system insta-
bility resulting in alarm or trip. Thus it is necessary to bleed all gas from all the
sensing lines prior to differential pressure adjustment to ensure optimum regulator
valve performance.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116742 Shaft Sealing System

E. Adjustment of the Pressure Regulator

1. Adjust the pilot-operated differential pressure regulator valve to hold the shaft seal oil pressure as
read on the differential pressure gauge at about 6.5 psi (44.8 kPa) above machine gas pressure.
(the differential pressure gauge displays a value roughly 1 psi (6.9 kPa) above the actual 5.5 psi
(37.9 kPa) shaft seal oil vs. machine gas pressure reading due to oil head between the machine and
differential pressure gauge.

2. Confirm the adjustment by subtracting the reading from the machine gas pressure transmitter from
the seal oil feed pipe pressure reading, found at the end shield, to achieve a 5.5 psi (37.9 kPa)
differential.

3. If the differential between the machine gas pressure transmitter and the seal oil feed pressure is not
5.5 psi (37.9 kPa), adjust the differential pressure regulator accordingly. Ultimately the reading at
the differential pressure gauge should lie between 6-7 psi (41.4 – 48.3 kPa), however, the differ-
ential pressure reading between the seal oil pressure, found at the end shield, and the machine gas
pressure transmitter must be 5.5 psi (37.9 kPa).

To make the actual adjustment, remove the adjusting screw cap on the pilot valve and loosen the hex
nut. To increase the differential pressure setting, turn the adjusting screw clockwise; to decrease the
differential pressure setting, turn the adjusting screw counterclockwise. Tighten the hex nut while
holding the adjusting screw and replace the adjusting screw cap. Due to potential differing pipe run
lengths to the TE and CE, the seal oil pressure may differ among ends to maintain the nominal 5.5 psi
(37.9 kPa) differential pressure at each seal.

It should be noted that while the differential pressure regulator will hold a nearly constant 5.5 psi (37.9
kPa) differential over the entire range of casing gas pressures, slight manual adjustments may be re-
quired at some operating pressures.

F. Adjustment of the Seal Oil Pressure Switches

The seal oil differential pressure switches are adjusted to:

1. (LOW) Sound an alarm on the annunciator panel when the seal oil differential pressure drops to
approximately 4.5 psi (31.0 kPa) (low pressure switch).

2. (LOW/LOW) Start the DC emergency seal oil pump, begin the automatic purge sequence, and
sound an alarm on the annunciator panel when the seal oil differential pressure drops to approxi-
mately 3.5 psi (24.1 kPa) (low/low pressure switches).

To adjust the low-pressure switch, isolate the switch by way of the isolation valves and crack open
the drain valves until the differential pressure gauge reads 4.5 psi (31,0 kPa) above the machine gas
pressure. Make any internal adjustments necessary to the pressure switch to actuate the contacts when
this differential pressure is reached.

Further reduce the seal oil pressure at the differential pressure gauge to 3.5 psi (24.1 kPa) above the
machine gas pressure. Adjust redundant low/low pressure switches internally to actuate the contacts
at this pressure.

When the emergency seal oil pump has come into service, it will run for 30 minutes and then shut off
automatically.

8 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Shaft Sealing System GEK 116742

G. Shaft Seal Oil Flow Check

The total quantity of oil passing through the shaft seals may be determined by reading the flow meter.
The flow values should be equal to or less than those given on the Hydrogen Design Data sheet.

CAUTION

Seal oil might contain hydrogen, which, in contact with any ignition points will
lead to fire/ explosion.

NOTE

The main lubrication system should be properly supplying oil to the seals during
the following check of seal oil flows.

The hydrogen-side seal oil flow is determined by draining from the float trap assembly drain valve into
a measuring container for a fixed period of time. This can be done by bypassing the float trap by closing
the float trap inlet valve from the seal drain enlargement and the return valve back to the bearing drain
enlargement and opening the drain valve and upstream/downstream sight indicator isolation valves.
Throttle the downstream bypass valve to hold the level of the sight indicator between the isolation
valves at approximately one-half full during the measuring period.

An alternative method of determining the hydrogen-side seal oil flow is to close the valve directly
upstream from the main float trap assembly drain valve and slowly drain oil from the float trap by
opening the main drain valve - maintaining the oil level within the sight glass of the float trap.

The total flow through the flow meter, minus the hydrogen-side flow past the main drain valve equals
the air-side flow.

After flow measurement, all valves should be returned to normal operating positions as per diagram.

H. Float Trap Vent Line

The float trap vent line valve back to the seal drain enlargement is normally left open; it is closed only
when it is necessary to isolate the float trap for servicing.

I. Operation at Reduced Gas Pressures

It may be necessary to operate with the float trap bypass open when operating at lower generator cas-
ing gas pressures in order to avoid flooding the seal drain enlargement. When the generator casing gas
pressure is low, approximately 5 psi (34.5 kPa) or less, the gas pressure in the seal drain enlargement
may not be sufficient to overcome the friction in the piping between the seal drain enlargement and
bearing drain enlargement, and flooding of the seal drain enlargement may occur. As casing gas pres-
sure builds up to approximately 5 psi (34.5 kPa), the bypass valve must be closed so that gas will not
be blown into the bearing drain enlargement. Bypassing is accomplished by operating the float trap
assembly and sight indicator valves as described in Section III.G.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 9

GEK 116742 Shaft Sealing System

J. Oil Filter Transfer

This section is applicable to units that have duplex filters. Only one filter housing is in service at one
time. Before switching filters, it is necessary to fill the alternate filter with oil, and vent the filter housing
to prevent air from being carried to the generator seal rings. When the transfer valve is in either extreme
position, it will circulate oil through one filter housing and, at the same time, shut off oil flow to the
idle filter. In the halfway position oil will flow through both filters. If the filter assembly is equipped
with a stand-by filter fill valve, it shall be used to fill the stand-by filter before transferring oil flow to
the stand-by filter. Open the fill valve and open the stand-by filter vent valve. Allow the filter to fill
with oil and vent any trapped air within the filter housing. Once stand-by filter is filled with oil, close
the fill valve and close filter housing vent valve. The filter transfer valve may now be used to transfer
oil flow to stand-by filter.

CAUTION

Incorrect transfer of oil filter housings can introduce large quantities of air into the
system, which can result in seal failure due to lack of lubrication. Lack of seal oil
will cause hydrogen gas to vent along the shaft resulting in a fire danger. Do not
attempt to transfer the filter until the filter to be placed in service is fully vented.

K. Oil Filter Cartridge Replacement

Change filter cartridges whenever the pressure drop across the filter reaches 6 psi (41.4 kPa) as indi-
cated on the differential pressure gauge, which is mounted on the switch and gauge panel. The filter
differential pressure gauge has an alarm switch set at 8 psid (55.6 kPa). The seal oil flow must be
transferred to the housing with clean filters as soon as possible when the alarm value is reached.

CAUTION

Failure to change filter cartridges when required may lead to high pres- sure drop
across the filter causing low oil flow to the hydrogen seal rings. This can result in
seal failure and fire danger.

10 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

Shaft Sealing System GEK 116742

PAGE LEFT INTENTIONALLY BLANK

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GEK 116742 Shaft Sealing System

g
GE Energy
General Electric Company
www.gepower.com

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DWG Number 110E7151 Rev C Released Page 1 of 2

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GE Proprietary Information - Class II (Internal) US EAR - NLR

Tab 23
 Hydrogen Gas System
for
BEARING
Hydrogen Cooled Generator
VENT HOUSING GENERATOR
FLOW
METER
H2 DIST. PIPE
TURBINE END COLLECTOR END
GAS GAS
ANALYZER ANALYZER
SCAVENGING LINE
FLOW FLOW
METER METER CO2 DIST. PIPE SEAL DRAIN
ENLARGEMENT
BEARING DRAIN

FLOAT TRAP
FILTER FILTER
DESICANT DESICANT
HIGH
OIL LEVEL
ALARM

MACHINE DIFF. FAN

PRESSURE PRESSURE AIR TEST/
PURGE
VENT

SPOOL REGULATOR SPOOL

PIECE PIECE
CORE
MONITOR
H2 CO2

GAS
DRYER

STF 11–26A 3/98

DWG Number 105T5012 Rev - Released 10/19/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T5012 Rev - Released 10/19/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T5012 Rev - Released 10/19/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 105T5012 Rev - Released 10/19/2012

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK103763 Rev G Released 8/6/2014 Page 1 of 44

GEK 103763g

g
August 2014

GE Power & Water

Hydrogen and Carbon Dioxide Gas Control System for

Non Packaged Units
Operation and Maintenance Instructions

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 2 of 44

GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 3 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

TABLE OF CONTENTS

I. GENERAL DESCRIPTION.................................................................................................................5
A. Why Hydrogen ................................................................................................................................5
B. Explosion Hazard.............................................................................................................................5
C. Inert Intermediate Gas......................................................................................................................5
D. Essential Parts of the Gas Control System ........................................................................................5
E. Gas Storage......................................................................................................................................7
F. Gas Valve Station ............................................................................................................................7
II. WARNINGS CONCERNING THE USE OF HYDROGEN ...............................................................7
A. General Rules for Safe Handling of Hydrogen..................................................................................7
B. Unknown Contaminant is Assumed to be Air ...................................................................................7
C. Rules for Safe Handling of Hydrogen...............................................................................................7
D. Maintenance on Hydrogen Equipment..............................................................................................8
E. Hydrogen Zone ................................................................................................................................8
III. GENERAL DESCRIPTION OF THE GAS CONTROL SYSTEM....................................................9
A. The Rotor Fan..................................................................................................................................9
B. CO2 as Intermediate Gas ..................................................................................................................9
C. Distribution Pipes ............................................................................................................................9
D. Gas Control Valves ..........................................................................................................................9
E. Casing Liquid Detector ....................................................................................................................9
F. Shaft Sealing....................................................................................................................................9
G. Seal Oil Draining ...........................................................................................................................10
H. Oil Deflectors ................................................................................................................................10
I. Gas Flow Between Cavities............................................................................................................10
J. Scavenging to Retain H2 Purity in the End Cavities ........................................................................10
K. Vacuum Seal Oil Systems ..............................................................................................................14
L. Gas Purity Monitoring....................................................................................................................14
IV. GAS CONTROL VALVE EQUIPMENT ..........................................................................................14
A. Features of the Gas Control Valve Assembly..................................................................................14
B. Features of Bottle Manifolds ..........................................................................................................17
C. Features in the Gas System Piping..................................................................................................17
D. Features of the Liquid Detector Assembly ......................................................................................17
V. OPERATION ......................................................................................................................................18
A. Operator Activities Start Up / Shut Down.......................................................................................18
B. Generator Gas Purging and Normal Operation................................................................................20
C. Setting the Scavenging Flow Rates.................................................................................................25
D. Operating the Generator at Full Speed with Air Inside....................................................................26
VI. ALARM RESPONSES........................................................................................................................27
A. Low-Low and Low Generator Gas Purity Alarms...........................................................................28
B. Generator Gas Temperature High...................................................................................................30
C. Generator Gas Pressure High .........................................................................................................30
D. Generator Gas Pressure Low ..........................................................................................................30
E. Liquid Detection ............................................................................................................................31
VII. MAINTENANCE ................................................................................................................................34
A. Leak Testing ..................................................................................................................................34
B. Regular Maintenance .....................................................................................................................34
C. Special Maintenance ......................................................................................................................36
D. If the Hydrogen Control Cabinet is Flooded with Oil or Water .......................................................36
E. Materials and Design Conditions....................................................................................................37
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without prior permission of the copyright owner.
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DWG Number GEK103763 Rev G Released 8/6/2014 Page 4 of 44

GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

VIII. OPERATION AND DESIGN REQUIREMENTS FOR THE H2 AND CO2 GAS SUPPLIES.........37
A. Requirements on Gas used in the Generator....................................................................................37
B. Characteristics of Compressed Gas.................................................................................................38
C. Carbon Dioxide in Pipes and Valves ..............................................................................................40
D. Sizing the Carbon Dioxide Flow Orifice.........................................................................................41
E. The Hydrogen Flow Orifice ...........................................................................................................42
F. Sizing the Manifold Pressure Regulator Valves ..............................................................................42
G. Calculating the Quantity of CO2 Bottles Required to Purge a Generator..........................................42
H. Calculating the Quantity of H2 Bottles to Purge and Fill the Generator ...........................................43

LIST OF FIGURES

Figure 1. Represents a typical generator gas control system with all possible accessories ..................................6
Figure 2. Gas Control Valve Assembly ...........................................................................................................11
Figure 3. H2 or CO2 Bottle Manifold ...............................................................................................................12
Figure 4. Liquid Level Detector Assembly......................................................................................................13

LIST OF TABLES

Table 1. Purge Activity Parameters .................................................................................................................21

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 5 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

I. GENERAL DESCRIPTION

This manual provides operation and maintenance instructions for the H2/CO2 piping and other equipment
which is external to the generator. This manual applies to unpackaged generators. This includes all
generators with water cooled stators, as well as 7FH2LD, and 324, 330H, 390H, 450H leads up and leads
down.

A. Why Hydrogen
The generator interior components are cooled by convection whereby a gas transports heat to the
generator gas/water heat exchanger. Generator windage losses are greatly reduced with hydrogen
rather than air as the gas inside the generator because hydrogen has a lower density. In addition,
compared to air, hydrogen has greater thermal conductivity and convection coefficients. The
generator gas thermal capacity is further increased by the use of pressurized hydrogen. The sealed
environment necessary to contain hydrogen has the secondary benefit of keeping the generator parts
clean.

Also, hydrogen, rather than air, greatly reduces armature insulation deterioration caused by corona.

B. Explosion Hazard
Hydrogen must be handled carefully to prevent catastrophic oxidation. The gas control valves
provide a means for safely handling hydrogen.

C. Inert Intermediate Gas

An inert gas, carbon dioxide, is used as an intermediate gas so that air and hydrogen do not mix
inside the generator. The purging procedure for the generator has carbon dioxide introduced to
displace the air, then hydrogen introduced to displace the carbon dioxide. The generator is then
pressurized with hydrogen and the pressure is maintained automatically with a control valve. The
generator may remain pressurized with hydrogen during short outages even if the shaft is not on
turning gear. Prior to opening the generator for maintenance, the hydrogen is depressurized, and then
carbon dioxide is introduced to displace the hydrogen. Air is then introduced to displace the carbon
dioxide, and the end shields can be opened. During an emergency it is important to at least purge the
generator of hydrogen by introducing carbon dioxide.

Gas control during the purge operations is performed manually at the gas control valve station.

D. Essential Parts of the Gas Control System

The gas control system has these primary parts:

1) Generator, with gas piping connections

2) Gas Piping with Valving
3) Gas Control Valve Assembly
4) Hydrogen Control Cabinet, primarily for gas purity analysis
5) Hydrogen Gas Storage
6) Carbon Dioxide Gas Storage
7) Liquid Level Detectors

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without prior permission of the copyright owner.
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DWG Number GEK103763 Rev G Released 8/6/2014 Page 6 of 44
GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units
Figure 1. Represents a typical generator gas control system with all possible accessories
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without prior permission of the copyright owner.
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DWG Number GEK103763 Rev G Released 8/6/2014 Page 7 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

E. Gas Storage
The source of the hydrogen or carbon dioxide is out of the scope of the equipment provided with the
generator. Some power plants have bulk supply systems, some use bottle manifolds, other have a
combination of the two systems. GE does offer bottle manifolds if requested by the customer, and for
those facilities which use those manifolds, instructions are provided in this document.

The bottle manifolds for CO2 or for H2 may or may not be located near the gas control valves,
depending on the design of the facility.

F. Gas Valve Station

The gas control valves are located in the gas control valve station of the power plant. It is good to
place the gas dryer (if there is one), liquid level detectors, seal oil drain float trap and other
equipment in the vicinity of the gas control valves to reduce the number of hydrogen zones in the
power plant. The hydrogen control cabinet, or a generator gas purity display, or other means of
monitoring hydrogen purity should be available at the gas control valve station.

II. WARNINGS CONCERNING THE USE OF HYDROGEN

Hydrogen and air form a highly explosive mixture if concentrations are between 4.1% and 74.2%
hydrogen by volume in air.

When completely assembled and operated in the proper manner, the generator casing, which forms the
hydrogen container, is a gas tight enclosure.

A. General Rules for Safe Handling of Hydrogen

Precautions must be taken to safeguard against a hydrogen explosion.

1. Never permit an explosive mixture to exist.

2. Eliminate any possible source of ignition.

B. Unknown Contaminant is Assumed to be Air

Any unknown contaminant in the hydrogen gas shall be assumed to be air. The exception is that if the
hydrogen is supplied directly from a hydrogen generation device, which derives the hydrogen from
splitting water to hydrogen and oxygen, then the policy may be to assume that any unknown
contaminant will be assumed to be pure oxygen. Hydrogen and oxygen form an explosive mixture
with approximately 96% hydrogen (4% oxygen) by volume.

During the carbon dioxide purge the contaminant is known to be carbon dioxide. If the seal oil is not
being vacuum treated and the seal oil system is operating normally, the contaminant may be assumed
to be air. At any other time, the contaminant is not known and shall be assumed to be air except as
noted immediately above.

C. Rules for Safe Handling of Hydrogen

The procedure for purging the generator is designed to prevent explosive mixtures. The purging steps
of removing spool pieces, disconnecting bottles, and disconnecting the air supply must be strictly
adhered to. In addition.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 8 of 44

GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

1. Do not have a permanent air supply connected to the generator, the hydrogen control cabinet, or
any other device connected to the generator or gas piping. This practice prevents the possibility
of an explosive mixture inside the generator due to operator error or valve leakage.

2. The generator and all piping must be pressure tested with air or CO2 for leaks prior to
pressurizing the generator with hydrogen.

3. Hydrogen pressure inside the generator must always be higher than ambient to prevent air from
leaking in. If automatic controls are inoperative, the operator must manually maintain pressure.
Additionally, the seal oil systems requires a casing pressure of 2 psig (13.8 kPa-g) minimum to
drain correctly from the seal drain enlargement tank to the bearing drain enlargement tank. Note
that the float trap will have to be bypassed until a casing pressure of 15 psig (103.5 kPa-g) has
been attained.

4. No welding may be done on the gas system or seal oil system while there is hydrogen in the
generator.

5. The hydrogen is sealed at the shaft to casing interface by oil film seals. The operator must be
familiar with the shaft seal oil system prior to operating the generator gas system.

6. Avoid having high pressure hydrogen escape to the room because it can ignite itself due to self
generated static charges.

7. Hydrogen flame is nearly invisible. If operator suspects hydrogen is escaping into the work area
and desires to feel for a gas escape flow, he should not use his hand or anything combustible,
such as clothing.

D. Maintenance on Hydrogen Equipment

Components of the gas control system, which are intended for maintenance while the generator is
pressurized, are listed in a later section. Prior to maintenance, the operator should use, if available,
two valves rather than only one to isolate the work area from high pressure hydrogen. Also, prior to
opening a joint in a gas line, the operator should use, if available, a vent valve to depressurize the
equipment. Some components might not have the vent valve or the second set of isolation valves
close to the work site.

E. Hydrogen Zone
Electrical equipment in the vicinity of joints in hydrogen piping should not be sources of ignition.
The local or national codes pertaining to explosive atmospheres vary, and should be investigated if
the operator is suspicious of potentially sparking electrical equipment located in the vicinity of the
hydrogen equipment.

As a minimum, a Division 2 (or Zone 2) H2 atmosphere extends for 1.2 meters for 5 psig to 60 psig
(35 to 414 kPa–g, 0.352 to 4.22 kg/cm2) piping and 1.8 meters for 75 psig to 150 psig (517 to 1034
kPa–g, 5.27 to 10.55 kg/cm2) piping. It extends down 0.2 meters and up 4.2 meters. Potential small
leak sites are non–welded joints in piping, including flanges, valves, threaded joints, and O–rings and
compression fittings. The extent of the explosive atmosphere does not penetrate walls or other similar
barriers. Each piece of electrical equipment in the explosive atmosphere should have one of the
following: explosion proof housing with conduit or cable sealing, intrinsically safe circuit,
hermetically sealed contacts, non–sparking components, non–incentive circuit, forced ventilation
from a non–contaminated air source, or purging with pressurization.

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without prior permission of the copyright owner.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 9 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

III. GENERAL DESCRIPTION OF THE GAS CONTROL SYSTEM

A. The Rotor Fan
The generator gas is circulated inside the generator by a fan on each end of the rotor. The fan creates
a differential pressure of several inches of water. The fan blown hydrogen cools the generator rotor
windings, armature windings (unless these are separately cooled by water), and armature magnet
laminates. The fan blown hydrogen also is forced through a cooler, where it loses the heat it picked
up from cooling the generator electro–magnetic components. The fan differential pressure is used by
external gas system components, which require a small flow rate and need to return the gas to the
generator. Examples of possible equipment are (not necessarily supplied with every generator): gas
dryers, over–heating particle detectors, and gas analyzers.

B. CO2 as Intermediate Gas

The generator has a large open volume internally (1000 cubic feet (30 m3) or more). This volume
contains hydrogen during normal operation. It contains air during maintenance outages. An inert gas
is put into the generator volume as an intermediate gas so that air and hydrogen do not mix inside the
casing. Carbon dioxide is used as the inert gas because it has a substantially higher density and lower
thermal conductivity compared to hydrogen or air. The substantially different properties are used by
the gas analyzer (inside the hydrogen cabinet) so that gas concentrations during purging can be
monitored.

C. Distribution Pipes
Along the top of the generator interior is a long pipe with holes, which acts as a manifold for
admitting hydrogen. Similarly, along the bottom of the generator interior is a long pipe with holes for
admitting carbon dioxide. These are called the hydrogen distribution pipe and the carbon dioxide
distribution pipe, respectively. During a purge operation, when gas enters the generator through one
of the pipes, the gas, which is being displaced from the generator exits out the other pipe.

D. Gas Control Valves

The piping between the gas supply source and the generator typically has a set of valves, which the
operator uses for purging the generator. During this purge operation, the operator will look at the
hydrogen control cabinet (or a remote display) so that he knows when the gas concentration is high
enough to stop purging.

E. Casing Liquid Detector

Drain ports are located in the low points of the generator. Liquid that enters these ports is routed to
the generator casing liquid detector.

F. Shaft Sealing
The rotor of each generator extends beyond the generator casing at both the turbine end (TE) and the
collector end (CE). The two shaft to casing interfaces are sealed against hydrogen escape with oil
film shaft seals. The shaft seals are located to the inside of the bearings. The shaft seals require a
continuous supply of clean cool oil as supplied by the seal oil system.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 10 of 44

GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

G. Seal Oil Draining

Used seal oil inside the generator will drain to seal oil drain enlargements (one on the CE and one on
the TE) where hydrogen bubbles can come to the surface of the oil, and then to a common float trap
valve which reduces the oil pressure from generator pressure down to bearing drain pressure and
prevents hydrogen from escaping with the oil.

H. Oil Deflectors
There are three gas cavities inside the generator, called:

1. The Turbine End Seal Cavity,

2. The Generator Casing (where the generator windings are), and

3. The Collector End Seal Cavity.

Seal oil is restricted to the end cavities. These cavities are separated from each other by oil deflectors,
which are extensions of the casing that have a small clearance between the static hardware and the
rotor.

I. Gas Flow Between Cavities

Gas flow into and out of the cavities is limited to:

1. New clean hydrogen being introduced to the generator casing.

2. Gas to the hydrogen cabinet, en route to the scavenging valves and the cell blocks, being taken
from all three cavities but especially the end cavities because of the scavenging valves. (Vacuum
treatment seal oil system generators might not have a scavenging capability).

3. The end cavities are not connected to each other to the extent that gas cannot travel from one end
to the other. Therefore gas flow is limited to traveling from the generator casing to the end
cavities.

J. Scavenging to Retain H2 Purity in the End Cavities

The end cavities include the seal oil drain enlargements. In these containers there is a net transfer of
air escaping solution from the oil and also hydrogen entering solution into the oil. The resulting effect
is that the end cavities have a relatively high concentration of air.

For generators, which have non–vacuum treated seal oil, the hydrogen cabinet has scavenging valves
through which the contaminated hydrogen is slowly exhausted to a vent. New clean hydrogen from
another part of the hydrogen system piping enters the generator casing to replace the scavenged gas.
By this process, the air contamination in the end cavities remains at a safe low level to avoid the gas
from being a combustible mixture. Also, the flow of gas across the thin gap of the inner oil deflector
retards the passage of the air contamination from entering the generator casing. Air contamination in
the generator casing region decreases generator performance.

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g
Figure 2. Gas Control Valve Assembly
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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units
Figure 3. H2 or CO2 Bottle Manifold
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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

Figure 4. Liquid Level Detector Assembly

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 14 of 44

GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

K. Vacuum Seal Oil Systems

Some generators have the seal oil treated in a vacuum chamber prior to the oil being exposed to the
generator gas. These generators would not require the scavenging valves to be open except during the
abnormal operation when the vacuum chamber does not have a vacuum or otherwise is not being
used. The hydrogen control cabinets provided with these generators might not be connected to the
seal oil drain enlargements.

L. Gas Purity Monitoring

The generator gas in the end cavities should be monitored in generators, which do not have vacuum
treated seal oil. If the seal oil is vacuum treated, then, it would be acceptable to monitor only the
generator casing gas. During the purging operation, the gas purity of the venting gas (the gas exiting
the generator) should be monitored.

IV. GAS CONTROL VALVE EQUIPMENT

The gas control valves provide the operator with an efficient and safe means of handling hydrogen. The
gas control valves can be roughly placed into these categories:

H2 Gas Storage (perhaps nothing more than a bottle manifold)

CO2 Gas Storage (perhaps nothing more than a bottle manifold and flow orifice)
H2 Gas Control Valves (part of the gas control valve assembly)
CO2 Gas Control Valves (part of the gas control valve assembly)
Purging Gas Control Valves (part of the gas control valve assembly)
Liquid Detectors
Interconnecting Piping and Valves

A. Features of the Gas Control Valve Assembly

The gas control valve assembly, Figure 2, is the operator’s control station during purging. There are
two main runs where gas flows from left to right. H2 is on the top run, and CO2 or air is on the bottom
run. There are two 3–way valves which operate in tandem. The top port of each 3–way valve
connects to the generator directly; the outside ports connect to H2 (on left) and CO2 (on right) and the
inside ports connect to the main vent. With the 3–way valve handles pointing down, the CO2 run will
be connected to the generator. With the 3–way handles pointing to the right, the H2 run will be
connected to the generator. Specific features on the gas control valve assembly are:

1. H2 Gas Control Valves

a. Hydrogen Inlet Pressure Relief Valve (PSV-2923). Pressure will be automatically relieved to
the piping design pressure if there is a pressure regulation malfunction, such as a leaky valve
seat, in the hydrogen supply system upstream of the gas control valves.

b. Hydrogen Pressure Breaker Valve (HV-2925). The operator can de–pressurize the hydrogen
supply system by opening this valve.

c. Hydrogen Spool Piece. The operator is required by the equipment configuration to remove
this segment of hydrogen pipe in order to connect an air supply to the generator.

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 15 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

d. Hydrogen Inlet Pressure Instrumentation (PI-2930). A gauge provides information to the

operator that there is hydrogen pressure available for the generator. A low pressure switch
will inform the operator that the supply system has insufficient pressure and that
maintenance, such as replacing hydrogen bottles, is required.

e. Connection for Hydrogen Cabinet Calibration (LE004). A port is provided on the gas valves
so that pure hydrogen can be supplied to the hydrogen cabinet for calibrating the gas
analyzers.

f. Connection for Portable Gas Analyzer (LE033). A port for providing pure hydrogen for
calibrating an auxiliary gas analyzer is provided for customer convenience.

g. Generator Gas Flow Control Pipe Restriction. This orifice regulates the flow rate of hydrogen
during the purging step that has hydrogen being admitted to the generator. It is manufactured
inside the piping to reduce the number of joints.

h. Generator Gas Pressure Regulator (PCV-2935). A pressure regulator is provided as an

automatic pressure control to replace small amount of generator internal gas used by the gas
analyzer, gas that has gone into solution with the draining seal oil and gas which may slow
leak out the casing joints. When carbon dioxide is being admitted into the generator an
isolation valve in series with this regulator is closed. During purging, the gas goes through
this regulator, and it is full open because during purging generator gas pressure is well below
the regulator set point.

i. Generator Gas Pressure Regulator Bypass Valve (HV-2935). The Generator Gas Pressure
Regulator is not used during the initial generator pressurization. During this operation the
bypass valve is open.

j. Hydrogen Secondary Block Valve (HV-2936). A second block valve is provided for
redundant hydrogen isolation. It would be closed if the Generator Gas Pressure Regulator is
removed for maintenance.

2. CO2 Gas Control Valves

a. Carbon Dioxide Pressure Relief Valve (PSV-2940). Pressure will be automatically relieved
to the piping design pressure if there is a pressure regulation malfunction, such as a leaky
valve seat, in the CO2 supply system upstream of the gas control valves.

b. Carbon Dioxide / Air Spool Piece. Prior to air being admitted to the generator, this spool
piece will have to be removed from the carbon dioxide line and placed into the air line. When
in the air line, it will be impossible for either hydrogen or carbon dioxide to be admitted to
the generator.

c. Carbon Dioxide Supply Pressure Gauge (PI-2944). A gauge indicating carbon dioxide supply
pressure is provided for the operator performing the purging operation.

d. Other Ports in the Carbon Dioxide Line. In the carbon dioxide line there are utility ports
which, might not be used: hydrogen cabinet gas analyzer calibration (LE055), gas dryer
purge (LE008), and one un–assigned. A port for portable gas analyzer calibration (LE013) is
provided for customer convenience.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

e. Carbon Dioxide Shut Off Valve (HV-2946). The carbon dioxide shut off valve is closed
except when carbon dioxide is admitted to the generator. If it is open during normal
operation, carbon dioxide may leak into the generator.

f. Air Shut Off Valve (HV-2947). The air shut off valve is closed except when air is admitted to
the generator.

g. Temporary Air Connection (LE009). A port is provided for clean dry air so that the generator
can be filled with air prior to opening a cover on the generator.

3. Purging Control Valves

a. Three–Way Valves (HV-2952/HV-2955). Each of the two three–way valve handles should
always be in the same position as the other. In one configuration the hydrogen control valves
are connected to the generator and in the other configuration the carbon dioxide control
valves are connected to the generator. In both configurations the generator is connected to the
vent valve.

b. Check Valves (CV-2950/CV-2940). There is a check valve in the supply line immediately
adjacent to the three–way valves. The check valve prevents generator gas from back–flowing
up the hydrogen or carbon dioxide supply lines.

c. Vent Valve (HV-2954). The main vent valve has 2 modes of operation: (a) Fully open to
de–pressurize the generator, (b) Partially open during the purge operation to maintain
generator internal pressure a few psi (several kPa, a fraction of a kg/cm2) above ambient.

d. Port in Vent Line for Gas Analyzer (LE056). The port in the vent line for the gas analyzer
has a projection into the vent line so that it senses total pressure (which equals pressure plus
the kinetic energy of the gas flow). It is ported to the hydrogen cabinet gas analyzer for use
by the operator during purging so that he knows when to stop purging.

e. Port in Vent Line for Portable Gas Analyzer (LE034). An additional port is placed in the vent
line with a total pressure port for use with a portable gas analyzer. It is provided as a
convenience to the customer.

f. Generator Gas Pressure Instrumentation (PI-2950/PT-2950/PSL-2950). A gauge and

high/low pressure switches for generator gas pressure are provided on the assembly.

g. Generator Gas Pressure Relief Valve (PSV-2950). A relief valve is provided so that during
normal operation, generator casing pressure does not increase above the capability of the seal
oil system. There is a flow restriction upstream of it so that it has more flow capability than a
failed open generator gas pressure regulator, but not so much that the generator
de–pressurizes rapidly if it itself fails open. The flow restriction is inside the pipe so that the
number of piping joints is reduced.

h. Vent Stack Drain Valve (HV-2943). A valve is provided on the bottom of the vent stack so
that condensation can be removed. Water condensed in the pipes leading to the generator
would also drain down to this valve during outage times. A slight bit of oil may be mixed
with the water.

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

B. Features of Bottle Manifolds

If a hydrogen gas bottle manifold is provided, it has these features. The carbon dioxide bottle
manifold has the same features:

1. Pigtails, one for each hydrogen gas bottle. There is a check valve on the manifold end fitting of
each pigtail.

2. Globe Valve, one for each hydrogen bottle.

3. Pressure Regulator Valve. These valves drops the pressure from the high bottle manifold
pressure down to approximately 125 psig (862 kPa–g, 8.79 kg/cm2) as required by the
downstream flow regulation restriction. Gauges are provided on the regulator valve.

4. Pressure Regulator Bypass Valve. The bypass valve should be opened or closed completely and
not put into a partially open position.

C. Features in the Gas System Piping

1. CO2 Flow Regulation Orifice. The CO2 piping upstream of the gas control valves should have a
flow regulation orifice to control flow rate during the purge step which admits CO2 into the
generator. Downstream of this orifice there should be a section of large diameter pipe where
solid CO2 precipitation can accumulate.

2. Drip Legs. Low points in pipe runs are provided with one or two valves. Accumulated liquid can
be drained. If there is only one valve, then either the pipe must be isolated or the generator
degassed prior to draining the liquid. If there are two valves, then the liquid can be drained by
alternating the valves between open and closed. Drip legs are placed in piping so that
condensation and other contamination are routed away from sensitive equipment.

3. Valves on the Underside of the Generator. There are several types of gas connections to the
generator: low point drains, gas feeds and vents, and pipes to gas sensing and gas processing
equipment. Many of these have isolation valves at the generator connection to assist in
maintenance.

4. Equipment Isolation Valves. Most pieces of equipment have isolation valves so that they may be
repaired on line.

D. Features of the Liquid Detector Assembly

The liquid detector assembly has these features for each detector: isolation valve, drain valve, sight
glass, fill port for test, and the sensor.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

V. OPERATION
A. Operator Activities Start Up / Shut Down
1. Pre-Start-Up

a. Read the warnings concerning the explosiveness and combustibility of hydrogen, which is in
an earlier section of this document.

b. Ensure the piping to the cabinet and the piping of the gas valves used for gas control are
correctly installed.

c. Ensure the external wiring of gas system electrical equipment is correctly installed.

d. Inspect the gas system equipment for damage. Drain out liquid, which may have accumulated
in the piping.

e. Be familiar with the operation of the seal oil system and the generator gas control system.

f. Be familiar with the use of the hydrogen control cabinet for gas purity monitoring.

g. Ensure there is enough CO2 available to purge out the air plus enough CO2 to purge out
hydrogen should there be an emergency.

h. Ensure the gas valves are in the correct position for the admission of carbon dioxide.

i. Energize the hydrogen control cabinet and prepare it for use.

j. Energize all seal oil pump motors, including all AC and DC, and all primary, backup, and
emergency pump motors.

2. Leak Test Piping.

After installation and prior to introducing hydrogen to the gas system equipment, all parts of the
gas system should be air tested to ensure there is no leakage. A similar, perhaps coinciding, test
should be performed to the generator casing and end shields. The air test may be performed with
CO2 after purging out the air if additional CO2 is available to be used to increase the pressure to a
usable level for leak testing.

Leaks can be identified by applying a soapy solution to the joints and welds. A typical solution
would be liquid soap, glycerin and water. Bubbling will indicate leakage.

3. Start–Up.

The seal oil system should be started when the admission of carbon dioxide into the generator
casing has raised the internal pressure to 2 psig (13.8 kPa-g). The pressure forces the seal oil to
drain through the float trap valve flow restriction. Initially, as pressure builds, seal oil may begin
to flood the seal oil drain enlargement. It is important that the seal oil not build up to the extent
that it floods the generator.

Therefore an operator should manually bypass the float trap temporarily until the generator
casing pressure is 15 psig (103.5 kPa-g).

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

Start–Up Steps:

a. Manually open the float trap bypass valve. (See Section V.B.5 Page 26 for further float
trap bypass instruction details.)
b. Start pressurizing the generator casing with CO2.
c. Turn on the seal oil supply system once the carbon dioxide pressure reaches 2 psig (13.8
kPa-g).
d. As the pressure inside the generator increases, the float trap bypass valve should be
manually closed, starting no earlier than 5 psig (34.5 kPa-g) and reaching full closed
position at 15 psig (103.5 kPa-g).
4. Purging and Other Normal Operations.

Please see below for other operator activities.

5. Shut–Down.

Prior to turning off the seal oil system, the generator should be purged so that hydrogen is not
present in a dangerous concentration. If maintenance activity is required inside, beneath, or near
the generator, or if the down time will be more than a few hours, then the carbon dioxide should
be purged out and replaced with air. After the purging steps are complete:

a. Reduce the Carbon Dioxide pressure by venting.

b. As the pressure inside the casing falls to 15 psig (103.5 kPa-g), begin to open manually the
float trap bypass valve. The valve should be completely open when the internal pressure
reaches 5 psig (34.5 kPa-g).

c. Turn off the seal oil supply system when the internal pressure reaches 2 psig (13.8 kPa-g).
This prevents flooding of the generator or hydrogen control cabinet with oil.

d. Open the generator vent valve.

WARNING

DO NOT OPEN THE GENERATOR END SHIELDS OR OTHER

ACCESS COVERS UNTIL THE OPERATOR IS SURE THAT THERE IS
NO PRESSURE INSIDE THE GENERATOR.

e. Use compressed air or large fans to blow CO2 out of low spots in the generator after opening
the generator.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

B. Generator Gas Purging and Normal Operation

The generator is purged with gases before and after normal operation of the generator.

1. Purge Table

Perform the operations per the following chart. Please read the clarifying notes below.

2. General Information on Purging

Estimated Time of Purge = Volume of Gas in the Generator / Flow Rate

Recommended Flow Rates of CO2 and H2. The recommended carbon dioxide flow rate is 120
scfm (3.4 s m3/minute) for a 2800 ft3 (80 m3) generator internal volume. The recommended
hydrogen flow rate is 50 scfm (1.4 s m3/minute) for a 2800 ft3 (80 m3) generator internal volume.

When hydrogen is purging the carbon dioxide from the machine in preparation for normal
operation, the gas speed in the feed piping shall be 300 feet per second maximum. Higher speeds
are permitted in the vents if compressible gas friction affects are considered. These flow rates are
approximate, and for generator volumes greatly different from 2800 ft3 (80 m3), the
recommended flow rate would change proportionally with generator volume (for example, twice
the flow rate if the generator is twice as large). Gas flow rates during purging shall be slow
enough to take advantage of the buoyancy effect of the gases inside the generator so that mixing
is avoided. This will minimize the customer’s gas usage during the purge.

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

Table 1. Purge Activity Parameters

Activity Air to CO2 CO2 to H2 H2 fill Normal degas H2 to CO2 to

CO2 Air
Estimated Time 0.5 2.0 1 N/A 0.5 1 N/A
(hrs)

Recommended Flow 3.4 1.4 N/A N/A N/A 3.4 N/A

Rate* 120 50 N/A N/A N/A 120 N/A
3
(s m /hr) 3 5 N/A N/A N/A 3 N/A
(scfm)
(minutes per bottle)
Amount of Gas 1 2 n N/A 0 2 >3
(x Generator
Volume)
Hydrogen Control
Cabinet Controls
“Mode” Selection Purge Purge N/A Normal N/A Purge Purge
“Function” CO2 in Air H2 in CO2 H2 in Air H2 in H2 in H2 in CO2 in
Selection CO2 Air
Air Air
Stop % 70% CO2 90% H2 N/A N/A N/A 5% H2 5% CO2
Gas Valve Station
Valve Positions
3–Way Valves down right right right either down down
Main Vent Valve partially partially closed closed full partially partially
open open open open open
Generator PCV closed open open open closed closed closed
Isolation Valve
Generator PCV closed closed open closed closed closed closed
Bypass Valve
CO2 Shut–Off Valve open closed closed closed closed open closed
Air Shut–Off Valve closed closed closed closed closed closed open
H2 Spool Piece out H2 line H2 line H2 line H2 line either out
position
CO2 Spool Piece CO2 line CO2 line CO2 line CO2 line CO2 line CO2 line air line

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

Automatic Flow Control of CO2 and H2 during Purging. The flow rate during purging is
automatically controlled by the size of flow restrictions which are integral with the equipment.

Bottles May Be Discharged Simultaneously. Two bottles would decrease in pressure in about
twice the time, three bottles in about thrice the time, relative to the time given on the table above.

Manual Generator Pressure Control during Purging. Because of the gas stratification due to
buoyancy, which occurs inside the generator, there will be very little if any change in gas
mixture in the venting gas for the first 2/3 of the purge time. During the last 1/3 of the purge, the
gas concentrations will change rapidly.

The generator vent valve (HV-2954) should be positioned and adjusted to hold between 2 and 5
psig (13.8 to 34.5 kPa–g, 0.14 to 0.35 kg/cm2) inside the generator. The generator pressure will
change, and the valve may need adjusting, during the final 1/3 of the purge because during that
time the gas density may change dramatically.

Quantifying Gas Quantity. Because gas is compressible and buoyant it is difficult to measure and
unnatural to perceive the concept of gas quantity. The mass of a sample of gas does not change,
although its volume may change due to the interactions of pressure, temperature, and density.
Therefore the best way to quantify gas quantity is by units of mass. However, because gas has
little weight and deforms and diffuses, the mass cannot be determined by measurement on a
weight scale. And units of mass do not have direct importance because gas is used for its
volume, not its mass, in most applications in mechanics.

Therefore, it has become the industry standard to describe gas quantity in units of “standard”
volume. The “standard” means that pressure and temperature are assumed to be at 14.7 psia (1
atmosphere at sea level, 101.4 kPa–a, 1.034 kg/cm2–a) and 77 °F (25 °C), respectively.
Sometimes the temperature standard is different, so it is important to know the specific standard
pressure and temperature, which are being used whenever a standard gas volume is given. The
actual pressure or temperature of a gas sample may be substantially different from the “standard”
conditions; however, the mass of the gas sample can be quantified by pretending it is at
“standard conditions”. For example, a bottle of compressed gas may have only a few cubic feet
of physical volume, but have hundreds of cubic feet (cubic meters) of “standard” volume worth
of gas because the gas can expand to the “standard” pressure.

This measurement system works because there is only one gas density corresponding to a
pressure/temperature combination for a particular type of gas. Therefore there is only one
“standard” density for a type of gas. The “standard” volume of a particular gas can therefore be
considered a measurement of mass.

“scfm” means “standard cubic feet per minute” (s m3/m “standard cubic meters per minute”).
“Standard” means the gas mass flow is equivalent to the volumetric flow if the gas were at 25 °C
(77 °F) and 1 atmosphere (14.7 psia, 101.4 kPa–a, 1.034 kg/cm2, which is 0 psig at sea level).
The “s” in front of “m3/hr” also means “standard”.

3. Purging With CO2

Low Pressure Means Less Gas Used. During the purge process the generator gas pressure should
be between 2 and 5 psig (13.8 to 34.5 kPa–g, 0.14 to 0.35 kg/cm2), preferably 2 psig
(13.8, kPa–g, 0.14 kg/cm2) by throttling valve HV-2954. A lower generator gas pressure requires

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

less purge gas. This is because purging is a gas displacement phenomenon, which is volume
driven, and higher pressure gasses have more mass (more gas) per a given volume. For example,
a 2800 ft3 (80 m3) generator will require one additional CO2 bottle of gas to displace H2 for each
psi (each 7 kPa, each 0.07 kg/cm2) additional gas pressure.

Low Flow Rate Means Less Gas Used. Flow rate during the purge is kept low to avoid mixing
the gasses inside the generator. The gasses are naturally separated by buoyancy.

Nitrogen Content of Air. The 70% CO2 in Air concentration is acceptable because it results in
only about 6% O2, the remainder being the inert gases N2 and CO2.

Purge Dead Cavities with CO2. After the generator is purged with carbon dioxide to 70% CO2 in
Air or 95% CO2 in H2, the generator gas pressure of a few psig (several kPa–g, a fraction of a
kg/cm2) should be used to purge the dead cavities of the generator. Most importantly, the seal oil
drain enlargements should be purged by simultaneously opening the scavenging valves long
enough to vent out 35 ft3 (1 m3) of gas. If there are volumes of air or H2 which cannot be purged
using generator CO2 pressure, then a portable CO2 supply should be used.

Purge Out H2 after Rotor has Slowed Down. Prior to admitting CO2, it is necessary to wait until
the rotor has decelerated to turning gear or stand still. A rotating shaft will mix the gasses inside
the generator. The mixing will destroy the buoyancy layering which keeps CO2 on the bottom
and H2 on the top. If the generator is to be purged while the shaft is rotating, there should be
sufficient CO2 available to account for the mixing. This can be several times the normal amount
of CO2 required for a purge.

Water Vapor Fog Layer. During the purge where cold CO2 replaces ambient temperature air, a
layer of condensed water vapor fog forms at the boundary of the two gasses. The optimum CO2
flow rate was originally calculated based on witnessing the movement of this fog layer.

4. Placing Air into Generator

The Removable Spool Pieces are designed to (a) inhibit the introduction of air while there is
hydrogen in the generator and (b) provide a means of absolutely preventing the inflow of
dangerous gas while personnel are inside the generator performing maintenance.

Air can have a high flow rate. Air is relatively inexpensive compared to H2 and CO2. Therefore,
the generator and the purge procedure are not designed to minimize the quantity of air needed.

So that there is no chance of mixing H2 and air together, air is introduced into the generator
through the CO2 distribution pipe on the bottom of the generator interior. Thus the lighter air is
below the heavier CO2, and the gasses thoroughly mix during purging. Because mixing cannot
be avoided, a very high flow rate of air can be used.

Air Supply Must Be Typically Disconnected. All air connections to the generator should be
disconnected when CO2 is admitted, and especially when H2 is inside the generator.

Remove Bottles and Spool Pieces Prior to Admitting Air. Prior to admitting air into the
generator, totally disable the CO2 and the H2 feed lines, which connect CO2 or H2 bottles to the
generator, to the hydrogen cabinet, and to all other equipment, such as a gas dryer. Closing
valves is not sufficient. The bottles should be removed, or the piping disassembled at a spool
piece or other fitting. If a workman is working on the generator, a dangerous situation can

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

develop by gas leakage through valves. CO2 is poisonous at moderately low concentrations and
H2 is explosive at concentrations above 4%.

Blow out CO2 from Low Spots in Generator. After the generator is purged with air, some CO2
will remain in the generator low points. After the end shield, bushing box cover, or other access
plate is removed, the generator should be blown free of CO2, either with a compressed air hose
or large fans.

Control Condensation During an Outage. During a generator outage the valves in the piping
should be closed so that humid atmospheric air does not enter the piping. Humid air will cause
condensation to form internal to the piping as ambient temperature fluctuates day to night.
Specifically, the valves on the underside of the generator should be closed. This will prevent
corrosion internal to the pipe and water build–up. Water which freezes could cause pipe rupture
and a resulting gas leak. Alternatively, to route condensed water to the vent stack, the three way
valve handles should be to the right.

5. Turning On and Off the Seal Oil Supply

Turning on the Seal Oil System. The seal oil system should not be turned on prior to the
generator internal pressure reaching 2 psig (13.8 kPa-g) of CO2. At this low pressure, the float
trap bypass valve must be open to prevent flooding of the generator or the hydrogen control
cabinet. Then the seal oil system may be turned on for the purge. While the bypass is used, it is
critical that the oil level not fall below the float trap. If this happens and there is hydrogen inside
the generator, hydrogen could enter the bearing area through the bearing drain enlargement. As
the generator internal pressure rises above 5 psig (34.5 kPa-g), the bypass valve should be
throttled, until it is fully closed when the generator internal pressure reaches 15 psig
(103.5 kPa-g).

Shutting Down the Seal Oil System. Under no circumstance should the seal oil system be shut
down while there is hydrogen in the generator. This procedure refers to after the hydrogen has
been purged out with CO2.

As the air purge reduces the generator internal pressure to 15 psig (103.5 kPa-g), the float trap
bypass valve should be manually opened, such that it is completely open when the internal
generator pressure drops to 5 psig (34.5 kPa-g). The seal oil system should be shut off when the
pressure inside the generator drops to 2 psig (13.8 kPa-g). The seal oil system should not be kept
operating if the pressure in the generator drops below 2 psig (13.8 kPa-g) because the flow
restriction of the float trap may cause flooding of the generator with oil.

6. H2 Purging, Filling, Normal Operation, and degassing

CO2 Must Always Be Available. The CO2 feed system for the generator should be continuously
operational during the H2 purge and normal operation. It may be necessary to emergency purge
out the H2 at any time.

Pressurize the Generator with H2 to a Slightly Lower Pressure. The generator does not need to be
filled to the full operating pressure, but rather about 10% low (relative to absolute pressure). The
gas temperature shortly after the purge and filling will be nearly ambient because of the huge
thermal mass of the generator electrical components. During operation the generator gas is much
warmer. By the perfect gas law, the pressure will increase as the temperature increases given a

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constant volume for the gas. Therefore, the pressure at the end of a fill should be per the table
below.

Pressure During Operation psig 15 30 45 60 75

Pressure After H2 Fill psig 12 25.5 39 52.5 66

Pressure During Operation kPa–g 103 207 310 414 517

Pressure After H2 Fill kPa–g 83 176 268 361 454

2
Pressure During Operation kg/cm 1.05 2.11 3.17 4.22 5.28
2
Pressure After H2 Fill kg/cm 0.84 1.79 2.74 3.69 4.64

Close H2 Feed When De–Pressurizing the Generator. When the operator opens the vent valve to
de–pressurize the generator, he should also close the hydrogen feed valve in the pipe leading to
the generator.

7. Hydrogen Control Cabinet Use During Purge

Hydrogen Control Cabinet Settings. The hydrogen control cabinet is the device which monitors
generator gas purity. “Purge” selection will control valves such that the gas sample is taken from
the generator vent. “Normal” selection will control valves such that the gas sample is taken from
the generator itself.

CO2 Contamination of Filters. Be sure the “purge” setting and not the “normal” setting is applied
to all applicable gas sensors of the hydrogen control cabinet when purging. This will prevent
CO2 from entering the filter dryers, which are molecular sieves. If CO2 enters the filter dryers it
will slowly bleed out over the first day of normal operation with H2 in the generator. If this
happens the reading will be inaccurate, in that it will indicate more air contamination in the
generator gas than is actually present during the first day of operation.

C. Setting the Scavenging Flow Rates

Generators which do not have vacuum treated seal oil should be provided with a means of
continuously bleeding out a small flow of generator gas from each of the two seal oil drain
enlargements. The seal oil drain enlargements are where air contamination will be introduced into the
generator because air comes out of solution from the seal oil. The gas control valves will
automatically introduce clean hydrogen into the generator casing when gas is bled out, with the result
of maintaining generator gas purity at an acceptable level.

The scavenge flow rate visual meters and hand operated control valves are typically located on the
hydrogen control cabinet. The flow rates should be set so that the end cavity generator gas purity is
maintained substantially above the Upper Explosion Level for H2 in air, see Table 1 above. The exact
value is dependent on the accuracy of the purity monitoring equipment and the operating philosophy
of the power plant (Refer to the international standard IEC 842 for guidance if no philosophy exists).

1. Start–Up

Initially, before there is any data or precedence on which to base the actual flow rate set point,
the valves should be set for removing about 1 scfh (472 ml/min) from each seal oil drain
enlargement. After several hours, which is a long time duration to ensure the system has

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stabilized, the flow rate can be changed. Higher flow rates will improve gas purity, lower flow
rates will degrade gas purity.

A high flow rate is not desired from an economic perspective because the scavenged gas is lost
to a vent.

2. After a Low Purity Alarm

There are three settings for scavenged gas purity: Control Set Point, Low Alarm, Low–Low
Alarm. The Low–Low Alarm point should not be below 80% H2 in Air by volume purity.

If the hydrogen purity in an end cavity drops to the low alarm, the operator should re–adjust the
scavenging rates to achieve the control set point. It may happen that the flow rate cannot be
increased further, in which case the generator should be shut down and purged of hydrogen so
that the cause of the problem can be fixed.

3. Trending

It is unusual to have a need to increase scavenging. Records should be kept and plotted so that
the two end cavity scavenging rates can be trended over long periods of time. Generator shaft
seal health, CO2 valve leaks, and other problems can be identified in this way.

4. Jumpy Flow Gauge

If the flow gauge for scavenging gas is jumpy, meaning the flow indicator moves every second
or so by itself, then the equipment can continue to operate until the next outage, at which time
the cause for the jumpy reading can be investigated and corrected. The correct reading of flow is
the average of the jumpy readings. Jumpiness is caused by liquid in the lines (so all drip legs
should be drained), or light solid blockage that moves back and forth. Flow through thermistor
based gas analyzers is also permitted to have some jumpiness.

D. Operating the Generator at Full Speed with Air Inside

During commissioning or another special circumstance, the generator may be required to operate at
full speed with air inside the casing. The shaft seals will need oil for lubrication during this operation
mode, and therefore the seal oil system must be operating, with the float trap bypass valve manually
opened. Without the valve opened, the seal oil, which drains to the generator side and out the float
trap, may back up into and flood the generator. Therefore, the generator should be pressurized with
air to 2 to 5 psig (13.8 to 34.5 kPa–g, 0.14 to 0.35 kg/cm2) and the float trap bypassed so that the oil
will drain properly. A higher pressure, about 15 psig (103.5 kPag), is necessary, if it is not possible to
manually monitor the float trap performance.

NOTE

It may not be possible to produce any electrical power under these circumstances.
Contact GE Product Services to determine operational limits.

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The generator fan differential pressure will increase proportional to gas density. Therefore it may be
3, 4, maybe 8 times as high as during normal operation with hydrogen inside the generator. The
generator fan differential pressure gauge may not be designed for the high differential service, and
may be required to be isolated so that its mechanisms do not get damaged. In particular, if the fan
differential gauge is a manometer, it must be isolated so that the heavy bromine liquid does not get
blown into the generator where it would cause corrosion.

The greater fan differential pressure may cause oil to be drawn into the generator unless: (a) the
pressure is kept high and (b) the vent lines, typically used for scavenging, on the two seal oil drain
enlargements are slightly open such that air is being vented from out of the generator through them.

The air supply should be clean and dry. A filter and an air dryer should be used. If a hydrogen gas
dryer is provided with the generator, it should be isolated from the system and not used unless the gas
dryer manufacturer specifically approves of its use as an air dryer.

VI. ALARM RESPONSES

Activation of any alarm requires prompt attention by the operator. Excessive delay in correcting an alarm
condition could result in damage to the generator and equipment, and possible injury to personnel.

Alarms in the hydrogen gas system are summarized below.

1. Operator Investigation: Further deterioration will not cause a generator load reduction nor an unsafe
condition:

a. Small accumulation of liquid in drip legs

b. Indications concerning humidity or the gas dryer equipment (if part of the gas system)

2. Operator Investigation: Operator attention is necessary at the soonest convenience:

a. High Generator Gas Pressure

b. Low Hydrogen Supply Pressure

c. High Generator Casing Liquid Detection

3. Operator Investigation: A generator load reduction or an unsafe condition is possible with further
deterioration:

a. Low Generator Gas Pressure

b. Low Generator Gas Purity

c. High Generator Gas Temperature

d. High–High Generator Casing Liquid Detection

e. High Seal Oil Drain Enlargement Liquid Detection

f. Insulation Overheating Particle Detection Alarm (Not provided with all generators)

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4. Manual Shutdown of Turbine–Generator

a. Low–Low Generator Gas Purity

5. Automatic Shutdown of Turbine–Generator:

a. None

6. Automatic Trip of Turbine–Generator

a. None

A. Low-Low and Low Generator Gas Purity Alarms

1. Assume Air is the Contaminant

Please read the warnings concerning hydrogen contamination as provided in the beginning of
this document. In particular, the contaminant is assumed to be air unless there is a reason to
suspect pure oxygen may be introduced. A condition to suspect pure oxygen is if the hydrogen
source is a hydrogen generation device.

2. Explosion Danger

Low purity is a concern primarily because of the hydrogen explosion danger.

3. Effect of Low Purity in Casing Gas

Low purity gas in the casing will slightly raise generator winding temperatures because air has a
relatively low thermal conductivity (about a tenth that of hydrogen’s) and air forms larger
boundary layer thickness which reduces convection. Also, air in the generator casing increases
windage losses and noise. Most generators have fan differential pressure indicators, which will
be reading noticeably high if the generator casing gas purity is below 90%.

4. Gas Purity Reading has a Time Lag

There is a time lag between the generator gas purity change and the monitoring of that change
due to the volume of gas in the interconnecting piping and the flow rate through that piping, as
well as contaminate diffusion which will occur in the piping. Given the flow rate, pipe size and
length, gas pressure ratioed to ambient, and a factor of 2 to account for diffusion, the operator
can calculate the time lag.

For example, a sensing line of 50 feet of pipe 0.5 inch diameter and a generator pressure of 60
psig with a gas flow rate of 2 scfh will have a time lag of

2 * 50 feet * (0.25 * pi * 0.5 * 0.5) in2 * (74.7 psia / 14.7 psia) * X / 2 scfh = 21 minutes X =
unit conversion factors (therefore X = 1)

For example, a sensing line of 15.24 meters of pipe 12.7 mm diameter and a generator
pressure of 414 kPa–g (4.22 kg/cm2) with a gas flow rate of 944 ml/minute will have a time
lag of

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2 * 15.24 m * (0.25 * pi * 12.7 * 12.7) mm2 * (414 + 101.4 / 101.4) * X / 944 ml/min = 21
minutes

X = unit conversion factors (therefore X = 1)

Therefore, while troubleshooting, the operator should remember that the purity reading is not
current.

5. Non–Vacuum Treated Seal Oil Systems

If there is a purity–low–alarm in an end cavity (not the generator casing), the rate of scavenging
should be increased to re–establish the desired set point reading. If purity cannot be maintained
between the desired set point and the low–alarm and if scavenging is at a maximum, then the
generator should be shut–down and the source of the contamination identified and corrected. Do
not operate the generator for more than a few minutes with purity less than the low–low–alarm
point.

6. Vacuum Treated Seal Oil Systems

Systems with vacuum treated seal oil are not susceptible to contamination in the end cavities and
therefore do not require scavenging from the drain enlargements. It is possible that the gas purity
monitoring equipment will only sample gas from the generator casing. The desired set point of
generator casing gas will be very high, approximately 95-98% and will not be adjustable because
there is no scavenging. The low–alarm point initiates operator investigation and the
low–low–alarm point would be used to advise the operator to shut down the generator.

If the vacuum treatment processing of the seal oil is being bypassed or is inoperative, then the
operator will have to scavenge gas from the seal oil drain enlargements. 35 standard cubic feet (1
m3) (about 1/6 of a bottle), (17.5 ft3 (0.5 m3) TE and 17.5 ft (0.5 m3) CE), of gas should be
scavenged every hour.

7. Sources of Contamination

Possible sources of contamination of the end cavity gas are (a) excessive seal oil flow, (b) poor
seal oil draining, (c) insufficient scavenging, and (d) excessive air in the seal oil supply.

The low purity in the casing may be due to a leaky CO2 valve. CO2 valves often corrode due to
an interaction of CO2 with humidity causing an acid to form, and so are susceptible to internal
leaks.

Moisture in the gas analyzer probe may cause erroneous readings. An alumina moisture indicator
should be upstream of the gas analyzer probe, and will warn of moisture contamination.

Moisture is often removed from the gas sample by a molecular sieve filter. This special type of
filter traps carbon dioxide and bleeds it out over a day or so. Therefore, if the carbon dioxide
from the purge operation was inadvertently routed to the filter, then the reading will erroneously
show low purity for about a day.

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B. Generator Gas Temperature High

If the generator casing gas temperature is too high there is a possibility of damage to the winding
insulation. The generator casing gas temperature alarm is part of the generator equipment, and not
part of the hydrogen gas system. Typically the alarm point is 2 °C (3.5 °F) above normal operating
gas temperature. After the alarm, cooling water flow should be increased or other action taken
immediately to lower the gas temperature. If the cause cannot be immediately corrected, the load on
the generator should be reduced until the normal gas temperature is obtained.

C. Generator Gas Pressure High

The generator gas pressure is maintained by a control valve in the gas control valve assembly. If the
control valve is found to be non–adjustable or otherwise malfunctioned, it can be isolated and
repaired. The generator can continue to operate with hydrogen being periodically provided through
the bypass valve around the control valve. Alternatively, if a two–stage pressure regulator is provided
on the bottle manifold, that regulator can be adjusted and used to control generator gas pressure
temporarily.

The primary concern with high generator gas pressure is that it will rise above the capability of the
seal oil system. By system design, this situation is unlikely.

D. Generator Gas Pressure Low

A low generator gas pressure of only a few psi (several kPa, several hundredth’s of a kg/cm2) will
cause several degrees C of elevated temperature in the rotor windings. Therefore it is important to
reestablish nominal generator gas pressure or else reduce load after a low generator gas pressure
alarm.

The generator pressure low alarm should be set within 2 psi (13.8 kPa, 0.14 kg/cm2) below nominal
generator gas pressure.

The generator gas pressure is maintained by a control valve in the gas control valve assembly. If the
control valve is found to be non–adjustable or otherwise malfunctioned, it can be isolated and
repaired. The generator can continue to operate with hydrogen being periodically provided through
the bypass valve around the control valve. Alternatively, if a two–stage pressure regulator is provided
on the bottle manifold, that regulator can be adjusted and used to control generator gas pressure
temporarily.

The other likely cause of a gradual lowering of generator gas pressure is low hydrogen supply
pressure or an extremely leaky vent valve.

If the pressure is dropping rapidly, the cause is possibly a failed open relief valve, a shaft seal failure,
a casing or pipe failure, or a failed open float trap valve in the seal oil drain system.

WARNING

IN CASE THERE IS A RUPTURE OF HYDROGEN CONTAINMENT,

THE GENERATOR SHOULD BE SHUTDOWN IMMEDIATELY, AND
IT SHOULD BE DETERMINED THAT THE AREA IS FREE OF H2 OR
CO2 HAZARDS BEFORE AN OPERATOR APPROACHES OR ENTERS
THE EQUIPMENT.

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Generators with autopurge feature will put CO2 into the generator automatically. The concentrations
of hydrogen in air, which are explosive, are between 5% and 75% hydrogen. During this emergency
period, while the generator is still charged with hydrogen, the seal oil system should be operating, in
spite of the fact it may be pumping oil into the generator. As the pressure drops below 15 psig (103.5
kPa-g) of CO2 or air, if it is possible to do so, the float trap bypass valve should be opened. As the
pressure of CO2 or air drops below 2 psig (13.8 kPa-g), the seal oil system should be shut down.

Hydrogen Supply Pressure Low

An indication of low hydrogen supply pressure is provided so that the operator can be prompted to
replace depleted hydrogen bottles and avoid the more critical event of a low generator gas pressure
alarm.

E. Liquid Detection
A liquid level alarm indicates either a water or oil leak inside the generator, or the seal oil drain
backing up.

Liquid oil and oil vapor (which easily condenses) create a sticky surface on the generator internal
surfaces and insulation. Dirt particles then have a tendency to stick to the oil surface and cling to the
insulation, and may eventually damage it. Liquid water on the insulation will degrade the quality of
the insulation.

There are two liquid level detectors that indicate potential oil or water ingress. The Seal Oil Drain
Enlargement (SODE) Liquid Level Detector monitors the SODE and detects and alarms when a high
seal oil drain enlargement level is reached. The Generator Liquid Level Detector monitors the
generator casing drains and detects and alarms both high and high-high liquid levels within the
generator.

The Seal Oil Drain Enlargement Liquid Level Detector high level alarm will typically indicate a high
seal oil flow situation due to a displaced hydrogen seal ring, worn or damaged seal ring, or a problem
with the drain system backing up.

The Generator Liquid Level Detector detects liquid has entered the generator, and steps should be
taken to determine if the liquid is water or oil. There are two sources of water: The hydrogen coolers
and the stator cooling water system (only provided if the armature bars are direct water cooled). Oil
in the generator casing indicates that oil supplied to the hydrogen seals assemble has migrated past
the inner oil deflectors or endshield splitline and into the generator.

1. Investigation

The following decision trees are a reference to assist the operator in troubleshooting the oil and
water systems to determine why a high and/or high-high alarm has triggered, and what actions
should be taken to mitigate the problem.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

WARNING

BOTH LIQUID LEVEL DETECTORS ARE CONNECTED TO AREAS

CONTAINING HYDROGEN GAS. EXTREME CAUTION SHOULD BE
TAKEN WHEN DRAINING LIQUID LEVEL DETECTORS SUCH THAT
HYDROGEN GAS DOES NOT ESCAPE THE SYSTEM. THE DOUBLE
ISOLATION VALVES ON THE GENERATOR OR DRAIN
ENLARGEMENT SIDE OF THE LEVEL DETECTOR MUST BE
CLOSED BEFORE OPENING THE DRAIN VALVE.

Seal Oil Drain Enlargement Liquid Level Detector High Alarms:

A seal oil drain enlargement liquid level high alarm indicates a high level of seal oil in the seal oil drain
enlargement. This indicates the seal oil drain is not discharging the seal oil quickly enough, causing oil
to backup in the system. This can be either from a high seal oil flow from the hydrogen seal assemble,
or a problem with the float trap and/or associated equipment, or a full or partial blockage in the seal oil
drain piping.

Generator Liquid Level Detector High Alarms:

The Generator Liquid Level Detector indicates that liquid has entered the generator casing. The first
step in investigating this alarm is to determine if the liquid is water or oil. Water can enter the
generator from the hydrogen coolers, or from the stator cooling water system if the generator armature
bars are direct water cooled. Oil in the generator indicates that seal oil from the hydrogen seal
assembly have migrated through the inner oil deflector or end shield splitline and into the generator.

To determine if the liquid is water or oil, the liquid level detector must be drained. The assembly has
two valves in series permitting the operator to open the bottom valve while the top valve is closed, and
in that way drain out the liquid which may have accumulated in the detector. The discharge port shall
be plugged with an NPT plug when not draining the liquid level detectors.

If the liquid is water:

- If the generator armature bars are direct water cooled, check the stator cooling water system to see
if a recent abnormal requirement for make-up water was required. If so, reference applicable GEK
for stator cooling water system.
- To determine if a hydrogen cooler is leaking, the operator can shut off water to one cooler at a time
if running at 80% load of rated load capacity and observe for the presence of a leak. If a cooler
leak is severe, the defective cooler may be left out of service with load reduced until repairs can be
made.

The hydrogen gas dryer, if provided, does not have the capability to dry the generator if there is a
generator internal water leak.

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If the liquid is oil:

- The following decision tree will help determine this issue, and begins with an investigation of the
float trap visual level gauge:

NOTE: This procedure assumes normal operating gas pressure inside the generator. The
seal oil drain system is designed to operate automatically with 5 PSIG or greater gas
pressure inside the generator casing. These procedures do not cover filling and purging the
generator with gas.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

2. Unseated Hydrogen Seal Rings

Hydrogen shaft seal rings may become unseated if there is a temporary reversal of pressure on the gas
side seal ring. This may occur during a transfer of one seal oil supply pump to another, due to a time
lag between pump stop and start, or a time lag in the seal oil pressure regulator valve response. An
unseated seal ring may cause an extremely large oil flow, which the drain system cannot drain quickly
enough. The seal rings often re-seat themselves shortly after the transient, but if the seal fails to re-seat
properly, the high flow rate can cause the drain system to back up. Oil then can migrate through the
inner oil deflector and into the generator.

If after going through the decision tree in above, the seal oil flow as read by the seal oil flow meter is
abnormally high, the operator can try to shock the seals back into place by quickly opening and closing
the seal oil pressure regulator bypass valve, which will pulse higher pressure oil toward the hydrogen
seal rings. This can be done a few times to see if the seals re-seat. If the seal re-seats, the operator will
note the seal oil flow return to normal levels by reading the local seal oil flowmeter.

NOTE: Note that during this procedure, another operator should be stationed at the float trap,
so that if the seal oil flow returns to normal, the float trap bypass can be closed, such that a liquid
level remains in the float trap. Failure to include this step as part of the procedure can result in
uncontrolled hydrogen loss though the float trap bypass valve.

If after performing this operation to attempt to shock the seal rings back to position, the seal oil flow
does not return to normal level, it is recommended that the power train be shut down to a standstill, the
generator purged of hydrogen, seal oil shut off, and the seal rings inspected and corrected, before the
generator fills with excessive amounts of oil.

VII. MAINTENANCE
A. Leak Testing
After a joint has been adjusted or otherwise loosened or tightened, such as after a component is
replaced, the joint must be pressure tested to ensure it will not leak hydrogen. Testing may be
performed with air or CO2, typically at approximately 20 psig (14 kPa–g, 0.14 kg/cm2).

Leaks can be identified by applying a soapy solution to the joints and welds. A typical solution would
be liquid soap, glycerin and water. Bubbling will indicate leakage.

B. Regular Maintenance
An operator should be available in the control room to receive alarms at all times.

Each mechanism in the gas control system should be inspected periodically to ensure it is functioning
properly.

1. Daily Inspections

Once a day the operator should review the transmitter signals from the gas system and compare
them with standard values. The standard values will be established from previous operation
experience. Also the transmitter signals should be compared with the previous days’ readings to
identify any trends. The gas control system transmitter signals are:

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a. Generator Gas Pressure

b. Generator Gas Purity

c. Core Monitor (Not provided with all generators)

d. Hygrometers (Not provided with all generators)

e. Once a day the operator should walk around the gas system equipment to look for anything
abnormal. The gas control system features to be daily inspected are:

f. All valves should be in the proper position

g. Check the sight glass in the gas dryer (if a gas dryer is provided and it has a sight glass)

h. Compare the reading on all the pressure gauges with standard values

i. Hydrogen control cabinet settings and indicators should be normal

j. Core monitor and pyrolysate collector should be operating normally (if provided with
generator)

k. Check the sight glass in both liquid detectors and the seal oil drain system float trap

l. Drain condensate or other liquid out of the main vent line

2. Weekly Inspections

Visually inspect the moisture indicators (MI-2971, MI-2972, and MI-2973). A blue medium
indicates dry hydrogen, while a pink medium indicates excessive moisture in the hydrogen gas
sample that may affect the stability of the Generator Gas Analyzers (GGA). Replace or
regenerate the Moisture Indicator and replace the Gas Purifier if the medium is pink. Refer to
Removal of Moisture Indicators and Gas Purifiers. Blow down purifiers by first removing cap at
the base of the isolation valve and then open the valve itself. It is advisable to have a container
available to collect any fluid contained within the purifier. Please refer to the provided Hydrogen
Control Panel Operation and Maintenance manual for further details covering how to perform
maintenance activities.

CAUTION

The Purifiers May Contain Hydrogen Gas; Use Proper Safety Precautions.

3. Inspections Every Six Months

a. Calibrate or otherwise perform maintenance on the hydrogen control cabinet as required

b. Perform a Core Monitor system test. (Core Monitor is not provided with all generators)

c. Check the calibration and operation of all the alarm devices and contacts

4. Inspections to be Done After Every Scheduled Purge with Carbon Dioxide

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Check all drip legs and other drains for liquid accumulation. If the generator is purged with air,
close isolation valves in piping at the generator and elsewhere to prevent humid atmospheric air
from entering the piping.

5. Generator Maintenance Outage

Test all the relief valves for a possible leakage into the vent lines. All gauges should be
calibrated every three years minimum.

C. Special Maintenance
1. Gas System Components Designed for Maintenance Activity

Tag all valves, switches, or other devices, which are important to be in a particular state during
the maintenance duration.

Do not disable the CO2 supply system at anytime for maintenance. CO2 must be continuously
available for an emergency purge.

Read the warnings concerning hydrogen which are at the beginning of this document. The
following gas system fluid processing components have been designed for maintenance while
the generator is operating normally:

a. Hydrogen supply pressure sensing devices

b. Generator gas pressure sensing devices

c. Pressure Regulating Valve

d. Pressure Relief Valves

e. Liquid Level Detectors

f. Core Monitor (Not provided with all generators)

g. Gas Dryer (if a gas dryer is provided)

h. Hygrometer Probes (if provided)

i. Hydrogen control cabinet (short duration only)

j. Because there are no compressed air sources permitted to be connected to the generator, it is
unlikely that a fast air contamination of the generator gas can occur. Therefore the hydrogen
control cabinet can be isolated for a short duration for simple maintenance activity (for
example, changing the filter cartridge).

D. If the Hydrogen Control Cabinet is Flooded with Oil or Water

If the generator is flooded with oil or water, then there is the possibility that the hydrogen cabinet
may also have been flooded.

After a flooding accident, all the tubing and components of the hydrogen cabinet should be cleaned
and dried. Oil flooding will require cleaning with alcohol or similar solvent (not methanol CH3OH
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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

because it deteriorates elastomeric seals). This will require some disassembly at tubing and NPT
joints. The filter–dryer cartridges will have to be replaced. The silica–gel will have to be replaced if it
was contaminated with oil. The cell blocks will have to be removed and flushed with alcohol to
remove oil from inside the thermistor chamber.

The cleaning should extend at least back to the last drip leg in the piping.

E. Materials and Design Conditions

The gas system piping and components are made of ASTM A105/A106 carbon steel, AISI
304/304L/316/316L stainless steel, or bronze.

The design pressure of the piping and assemblies is 150 psig (1034 kPa–g, 10.55 kg/cm2). Bottle
manifolds are designed to a higher pressure.

VIII. OPERATION AND DESIGN REQUIREMENTS FOR THE H2 AND CO2 GAS SUPPLIES

The gas system equipment supplied with the generator does not include the H2 and CO2 gas storage
equipment or the piping to connect the gas storage equipment to the gas system gas control valves. This
equipment is not provided because there are many alternative gas storage systems available to the power
plant designers and they should choose one, which best fits their needs.

The following section gives instructions on the design of the gas storage equipment and piping. It also
provides instructions to operators on how to use equipment, which is designed to these requirements.

A. Requirements on Gas used in the Generator

The sources of gas should be able to provide gas to the gas control valves to the following
requirements:

1. Carbon Dioxide

Phase: Vapor Phase. This includes the emergency event of a loss of AC power.

Purity: Commercially available purity grade.

Flow rate: 120 scfm (3.4 s m3/min) for a 2800 ft3 (80 m3) generator. Flow rate changes
proportionally with generator volume.

Pressure: 125 psig +/-10 psig (861.8 kPa-g +/- 68.9 kPa-g or 8.79 kg/cm2 +/- 0.70 kg/cm2)
(between the pressure reducing valve and the CO2 flow orifice). The CO2 pressure at customer
connection LE049 shall be approximately 2 psig (13.8 kPa–g, 0.14 kg/cm2) as determined by the
generator internal pressure.

Temperature: Low temperatures are acceptable.

Gas Quantity: There should be enough carbon dioxide available for an operator to purge the
generator of hydrogen during an emergency. Bottles should be stored near the manifold.

The flow rate and pressure requirements can be satisfied by the use of an orifice when designed
to the design requirements given below. Please note orifice is already provided for CO2 gas
flowing from the GE designed CO2 bottle manifold system.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

2. Hydrogen

Purity: 99.9% or better. (Note that hydrogen manufactured from some processes may contain
measurable hydrogen sulfide and should not be utilized)

Humidity: maximum of 0.1 gram of water per cubic meter of gas (0.00007 lbm/ft3) (Gas should
be desiccant dried.)

Flow rate: 50 scfm (1.4 s m3/min) during purging for a 2800 ft3 (80 m3) generator. Higher flow
rates are permitted during the generator fill operation. The gas flow rates in feed pipes shall be
limited to 300 feet per second maximum.

Pressure: 125psig +/-10 psig (861.8 kPa-g +/- 68.9 kPa-g or 8.79 kg/cm2 +/- 0.70 kg/cm2) during
purging and normal operation. During the generator fill operation the gas control valves have no
flow restriction smaller than a 1 inch (25.4 mm) diameter pipe, so the pressure downstream of
PCV-2935 will be between 2 psig (13.8 kPa–g, 0.14 kg/cm2) and full generator gas pressure as
determined by generator internal pressure.

Temperature: Low temperatures as experienced during the discharge of bottles are acceptable.

3. Air

Humidity: Air should be desiccant dried.

Cleanliness: Air should be filtered. No oil vapor is permitted.

Flow rate: No upper limit on flow rate. Maximum flow rate based on the pipe size restriction is
expected to be 150 scfm (4.2 m3 /min)

Pressure: Approximately 2 psig (13.8 kPa–g, 0.14 kg/cm2) as determined by generator pressure.
The gas valve piping has no flow restriction smaller than 1 inch (25.4 mm) diameter pipe.

Temperature: Should be between -20 and 120 °F (-28.9 to 48.9 °C).

Gas Quantity: Several generator volumes of gas will be necessary to purge the generator.

B. Characteristics of Compressed Gas

It is important that the operator become familiar with the behavior of compressed hydrogen and
carbon dioxide.

CAUTION

Compressed gas is dangerous. Be cautious when using compressed gas. Be alert to

kinked flexible pigtails, especially at the fittings, and to over–stressed metal tubing–type
pigtails. Replace damaged pigtails immediately. Be cautious of high pressure gauges by
minimizing the amount of time an operator stands in front of them. Read all warnings
provided by the gas supplier.

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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

1. Gas Bottles and Regulators

Regulators

Connecting Bottles: Prior to attaching a bottle, the dirt and dust in the valve outlet and in the
pigtail fitting should be completely removed. Dirt in a pressure regulator will cause it to leak
internally when it should have a tight shut off.

Slowly Open Valve. Bottle pressure should be applied to a pressure regulator by slowly opening
the bottle’s hand valve. This avoids damage to the regulator or a gauge by a pressure shock.

Replace Leaky Valve Seats. If the pressure downstream of the pressure regulator increases when
there is no flow, then the pressure regulator valve seat may leak. The seat should be replaced if it
leaks. If the pressure at the gas control valve assembly is at the pressure relief valve setting, then
the seat of the pressure regulator is likely leaking.

Low Flow Delivery Pressure. Single stage regulators (which have more flow capacity than two
stage regulators) have their delivery pressure set point established at a high flow rate. During low
or no flow, the delivery pressure set point is much higher. Therefore, if the gas system is
designed so that a tight shut–off is necessary (i.e., the manifold globe valves are open in a
“ready” mode), and then the low or no flow delivery pressure should be deliberately set below
the gas system relief valve setting. Otherwise, the gas from the bottles will seep out the relief
valve and not be available when needed.

H2 Bottles

Hydrogen bottle size: 239 standard cubic feet (6.77 m3) per bottle (about 200 ft3 (5.7 m3) is
usable because the pressure drops off during discharge). At 70 °F (21 °C) the pressure is 2400
psig (16.5 MPa, 169 kg/cm2).

Minimize Number of Active H2 Bottles. For safety reasons, as few bottles of hydrogen as
possible should be used during any one time during normal operation.

Do Not “Crack” Hydrogen Bottles: Unlike non–flammable gasses, it is not recommended to

“crack” hydrogen bottles prior to connecting them to a regulator of manifold since
“self–ignition” of the released hydrogen is likely to occur.

CO2 Bottles

Use Gaseous CO2 Only. Only bottles which discharge the vapor phase of carbon dioxide should
be used. Bottles which have a siphon tube so that they discharge liquid, or bottles with the
discharge port on the bottom so that they discharge liquid, are not to be used with the generator.
Liquid carbon dioxide is extremely cold and may adversely affect the welds in the piping. Also,
it will easily form solid carbon dioxide after dropping in pressure in a flow restriction and
potentially block the piping.

Carbon dioxide bottle size: 50 lbm (50 pounds mass, 22.7 kg) of gas per bottle. At 70 °F
(21.1 °C) the pressure is 850 psig (5.86 MPa, 59.8 kg/cm2) and the contents is about 45 lbm
(20.4 kg) liquid and 5 lbm (2.3 kg) gas. At 110 °F (43.3 °C) a full CO2 bottle will have 1800 psig
(12.4 MPa, 127 kg/cm2) of pressure, at 140 °F (60 °C), 2600 psig (17.9 MPa, 183 kg/cm2). The
pressure inside a carbon dioxide bottle decreases during discharge because the evaporating liquid
cools the bottle contents, thus lowering the vapor pressure.
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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

Usable CO2 — Freezing. A 50 lbm (22.7 kg) bottle has 435 standard cubic feet (12.3 m3) of gas.
However, the CO2 may freeze during the bottle discharge. A portion of the contents in a CO2
bottle will be liquid for bottle pressures between approximately 60 psig (414 kPa–g, 4.22
kg/cm2) and 1050 psig (7.24 MPa, 73.9 kg/cm2). During a bottle discharge, the fluid contents at
60 psig (414 kPa, 4.22 kg/cm2) will be at approximately -56 °C (-68.7 °F). As gas continues to
be depleted from the bottle, the liquid will transform into a solid.

Bottles initially at 30 °F (-1 °C) will discharge only 63% of their contents; bottles initially at
110 °F (43.3 °C) will discharge only 85% of their contents. The relationship between available
% and initial temperature is approximately linear (a mid point is 73% at 70 °F (21 °C)). Bottles
which are disconnected from the manifold will not continue to discharge their gas to the
generator as they warm up. Therefore, in systems with all the CO2 bottles connected to bottle
manifold connections, the bottle freezing phenomena has less of an effect.

Bottles which are partially depleted will return to the full bottle pressure of 850 psig (5.86 MPa,
59.8 kg/cm2) at 70 °F (21 °C) after they warm up if they have about 30% or more of the CO2 still
inside.

C. Carbon Dioxide in Pipes and Valves

During the purge step of admitting CO2 to the generator, the carbon dioxide should go through two
stages of pressure drop. The first is through a pressure regulator, the second is through an orifice. The
two could be combined into one orifice, but flow rate would then vary considerably with bottle
pressure.

CO2 Feed Piping Should Have a Region Where Solid CO2 Can Form. Carbon dioxide will form solid
precipitation as it goes through a flow restriction (such as a valve or orifice) if the pressure on the
discharge of the restriction is below approximately 60 psig (414 kPa, 4.22 kg/cm2) and the gas is
cold, such as during the second half of a bottle discharge. Therefore the piping should be designed to
accommodate a build–up of solid carbon dioxide and operating procedures should be set up to
periodically vaporize it by admitting warm CO2 or heat from another source.

The orifice which regulates carbon dioxide flow rate should be designed so that the precipitation
accumulates in a large diameter pipe. The large diameter pipe provides surface for heat transfer from
the ambient environment and will greatly extend the time before the solid carbon dioxide
accumulation restricts flow rate. Precipitation should not be directed into a globe valve or small
diameter pipe elbow. A well designed system will accommodate solid CO2 accumulation without
forming a blockage if the operators simultaneously open all the CO2 bottles which are connected to
manifolds.

If there is a pressure regulator on the bottle manifold, then it should be designed to have a discharge
pressure substantially higher than 60 psig (414 kPa–g, 4.22 kg/cm2), such as 100 psig (690 kPa–g, 7.0
kg/cm2) or 125 psig (862 kPa–g, 8.79 kg/cm2). In addition, it should have a flow rate capacity (in
scfm’s) greater than the flow rate expected through the orifice. If it does not have a high enough flow
rate capacity, then it will not pass enough flow to maintain the 100 psig (690 kPa–g, 7.0 kg/cm2) or
125 psig (862 kPa–g, 8.79 kg/cm2), and there will be a possibility of solid CO2 accumulating in the
small bore piping immediately downstream of the pressure regulator. More than one bottle manifold
pressure regulator can feed the orifice which regulates carbon dioxide flow rate. See regulator sizing
instructions below.

Vaporizing Solid CO2 Blockage. If the operator experiences blockage due to solid carbon dioxide
build–up in the piping, there are several methods of vaporizing it.
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Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

1. More Bottles Simultaneously to Avoid Rapid Boiling of CO2. Bottles which discharge too
quickly will have rapid boiling inside the bottle. The rapid boiling causes foam and splatter
which will transport liquid to the top of the bottle. If it is suspected that some liquid is being
discharged from the bottle, then more bottles should be discharged simultaneously. By having
more bottles discharge simultaneously, they each will discharge more slowly, and the boiling
will not be so rapid.

2. Less Bottles Simultaneously to Periodically Vaporize Solid CO2 Build–Up. If blockage is due to
solid carbon dioxide forming after a flow restriction, then less bottles should be discharged
simultaneously. For example, if the blockage occurs during the last few minutes of five bottles
being discharged, then there will be less blockage after four bottles are discharged. When the
next four bottles are initially discharged, the relatively warm carbon dioxide will vaporize the
solid carbon dioxide, which had accumulated.

3. Heating Pipes With Water. Water can be dripped onto pipes and valves to provide heat to
vaporize solid carbon dioxide.

CO2 Heaters May Not Operate In An Emergency. Even if the carbon dioxide is being electrically
heated, the system and operating procedures should be designed to accommodate solid carbon
dioxide precipitation and the operators should be familiar with effects of solid carbon dioxide. The
heater may not be available during an emergency situation if the AC electrical power is lost.

Optimal CO2 Storage and Piping Design. The best carbon dioxide supply system is one where there
are enough carbon dioxide bottles connected for fully purging the generator. The advantages are that
(a) the operator will not be busy removing and installing bottles in the event of an emergency purge,
and (b) the full contents of the bottles are available because bottles which have had solid CO2 form
will eventually warm up and discharge their remaining gas. It would also be advantageous if the
piping is designed so that all the bottles can be opened simultaneously without the possibility of solid
carbon dioxide accumulating to the extent that it blocks the pipe to the generator.

D. Sizing the Carbon Dioxide Flow Orifice

The CO2 orifice should be sized to provide the optimum flow rate of CO2 into the generator during
the purge process. A flow rate, which is too high, will waste CO2 because CO2 will mix with H2. A
flow rate, which is too low, will cause the process to outlast the DC seal oil pump battery life,
assuming the purge is being done because of an emergency after AC power is lost.

Optimum flow rate is 120 scfm (4.2 m3/min) for a 2800 ft3 (80 m3) generator interior. The optimum
flow rate is approximately proportional to generator volume. The orifice will have an upstream
pressure between 115 psig (792.9 kPa–g, 8.09 kg/cm2) and 135 psig (930.8 kPa–g, 9.5 kg/cm2) and a
downstream pressure between 2 psig (13.8 kPa–g, 0.14 kg/cm2) and 5 psig (34.5 kPa–g, 0.35
kg/cm2). Therefore flow through the orifice is choked (Mach Number = 1), greatly simplifying the
calculation.

Use the flow function relationship for choked flow, which is:

mass flow = area * (total pressure / sqrt (total temperature) ) * X

X = sqrt ( k / R ) * sqrt ( ( 2 / ( k+1 ) ) ^ ( ( k+1 ) / ( k–1 ) ) )

where R = 35.04 lbf*ft / lbm*R (0.1889 kJ/kgK) for CO2

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

and k = 1.29 for CO2

Given average upstream conditions of 125 psig (862 kPa–g, 8.72 kg/cm2) and -10 °F (-23.3 °C) and a
desired mass flow rate of 120 scfm ( 4.2 s m3/min), the effective area of the orifice is 0.0536 in2
(35.0 mm2). “The discharge co–efficient, Cd, for large pressure ratios such as this situation is 0.85
per “The Dynamics and Thermodynamics of Compressible Fluid Flow” by Ascher H. Shapiro (page
100).

Actual Area = Effective Area / Cd

The actual area of 0.063 in2 (42.5 mm2), the physical diameter of the flow restriction should be
between 0.283 (7.2 mm). A standard manufacturing tolerance can be applied to the orifice diameter.

The calculation method is given so that generators with gas volumes substantially different from
2800 ft3 (80 m3) can have their orifices custom sized. Note that area is proportional to flow and
inversely proportional to pressure.

E. The Hydrogen Flow Orifice

Because hydrogen does not form solid precipitation inside the pipe, the orifice may be in the vicinity
of valves. Therefore it is included in the gas control valve assembly, and does not have to be provided
by others.

F. Sizing the Manifold Pressure Regulator Valves

The pressure regulator valves have to be sized large enough to pass enough flow so that the
downstream orifice is the most restrictive component of the circuit, and therefore the orifice is the
device which controls the flow rate. This is especially critical for the CO2 circuit. If the CO2 manifold
pressure regulator valve is too restrictive, then the pressure immediately downstream of the regulator
will be below 60 psig (414 kPa–g, 4.22 kg/cm2) and solid CO2 precipitation would form in the thin
pipe after the bottled CO2 becomes cold.

A typical manifold regulator is the Victor SR–703–ME–996 (0780–0805). The Victor catalog
provides 2 data points for air with 125 psig (862 kPa–g, 8.79 kg/cm2) delivery pressure: (50 scfm at
200 psig) (1.4 s m3/min at 1.380 MPa, 14.07 kg/cm2) and (183 scfm at 2000 psig) (5.1 s m3/min at
13.8 MPa, 140.7 kg/cm2). The conversion factors from the catalog are 0.81 for CO2 and 3.79 for H2|.
Therefore, for CO2, the flow rates are (40 scfm at 200 psig) (1.1 s m3/min at 1.380 MPa, 14.07
kg/cm2) and (150 scfm at 2000 psig) (4.2 s m3/min at 13.8 MPa, 140.7 kg/cm2).

Given 40 scfm at 200 psig (1.1 s m3/min at 1.380 MPa, 14.07 kg/cm2), there would have to be three
(3) of this style regulator for 120 scfm (3.4 s m3/min). Below 200 psig (1.380 MPa, 14.07 kg/cm2),
some solid CO2 precipitation may form near the regulator. If only two (2) regulators are used, solid
CO2 precipitation may form with bottle discharge pressures up closer to 400 psig (2.76 MPa, 28.15
kg/cm2).

If there is one pressure regulator for each bottle manifold, then the operator should open bottles from
each of the manifolds simultaneously, so that all the regulators are in use simultaneously.

G. Calculating the Quantity of CO2 Bottles Required to Purge a Generator

It is important to have enough gas immediately available for a carbon dioxide purge of the generator
of hydrogen. A typical CO2 bottle, when fully charged, has 50 pounds (22.7 kg) of carbon dioxide.
When expanded and heated to ambient inside the generator, the typical bottle has 435 cubic feet (12.3

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DWG Number GEK103763 Rev G Released 8/6/2014 Page 43 of 44

Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units GEK 103763g

m3) of gas. Of this gas, a fraction, x, is available prior to the bottle being removed from the manifold.
If the bottle is not removed, x = 1. The fraction, x, may be less than 1 because of CO2 which freezes
in the bottom of the bottle.

Because some mixing of gas will occur during purging, twice the generator worth of bottled CO2 is
required to purge out hydrogen.

# bottles of CO2 = 2 * generator volume / ( x * volume of gas in a bottle)

Example: Therefore, for a generator of 2800 ft3 (80 m3) and bottles originally at 32 °F (0 °C) for
which x=0.64, 2*2800 / (0.64*435) = 21 number of bottles of CO2 are required to be available in the
event of an emergency purge.

H. Calculating the Quantity of H2 Bottles to Purge and Fill the Generator

The typical H2 bottle has about 200 cubic feet (5.7 m3) of usable hydrogen when warmed to ambient
temperature inside the generator. Because some mixing of gas will occur during purging, twice the
generator worth of bottled H2 is required.

# bottles for purging = 2 * generator volume / volume of gas in a bottle

Additional bottles of hydrogen are required to pressurize the generator. Conservatively, this quantity
is.

# bottles for filling = n * generator volume / volume of gas in a bottle

where n is chosen from the chart below:

n final generator (kPa–g) (kg/cm2 )

pressure (psig)
1 15 100 1
2 30 200 2
3 45 300 3
4 60 400 4
5 75 500 5

The total number of hydrogen bottles which should be available prior to putting hydrogen into the
generator is

# bottles of H2 = # bottles for purging + # bottles for filling

Example: To purge and pressurize a generator of 2800 ft3 (80 m3) to 60 psig (about 400 kPa or 4
kg/cm2), there should be 2*2800/200 + 4*2800/200 = 84 number of bottles available.

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GEK 103763g Hydrogen and Carbon Dioxide Gas Control System for Non Packaged Units

g GE Power & Water

General Electric Company
www.ge-energy.com

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 GEK 103611
January 1995

GE Power Systems
Generator

System Purging and Charging

(Manual Purge)

I. PURGING AIR FROM THE SYSTEM

(refer to Illustration of Valving Operation for Purging Air with CO2)

A. Calibrate the portable gas analyzer to measure the percentage of air in carbon dioxide as outlined in the
One Cell Thermal Gas Analyzer Equipment publication.

B. Rotate the three-way plug valve and open valve (52) in GCO line to pass carbon dioxide to the generator
casing.

C. Open valve (58) in the GHF line and valve (55) in the vent line permitting gas from the generator casing
to pass to the roof vent. It is, of course, necessary to have hydrogen supply valve (65) at the manifold
closed during this operation.

D. When purging air from generator, open several bottles of carbon dioxide at once to feed the manifold.
The flow rate from the manifold is controlled by GCO supply valve (51). Limit the flow rate of carbon
dioxide to the generator casing to approximately 50 cubic feet per minute [24 litres/s] to minimize waste
of carbon dioxide.

E. Connect the sensing tube of the portable gas analyzer to the GSS line and throttle valve (54) to pass suffi-
cient gas to the gas analyzer for reading the purity of the gas being purged.

F. Discharge carbon dioxide into the generator casing until the purity of the gas being discharged is less
than 30% air in carbon dioxide. The amount of carbon dioxide required to produce a 70% concentration
will be about 1.0x the gas volume of the generator casing.

G. After purging is completed, open all gas piping drain valves for a few seconds to purge the gas lines.

H. During this purging operation, the hydrogen bottles should be readied for charging the generator casing,
as this operation immediately follows the purging of the casing.

II. PURGING HYDROGEN FROM THE SYSTEM

When purging hydrogen from the casing, the previous procedure shall be followed except:

A. Calibrate the gas analyzer to measure the percentage of hydrogen in carbon dioxide.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 1995 GENERAL ELECTRIC COMPANY
GEK 103611 System Purging and Charging

B. Discharge the carbon dioxide into the generator casing until the purity of the gas being removed is less
than 5% hydrogen in carbon dioxide. The carbon dioxide required to provide a 95% concentration will
be about 2.0x the gas volume of the generator casing.

III. CHARGING THE CASING WITH HYDROGEN

(Refer to Illustration of Valving Operation for Charging with Hydrogen)

A. Connect the sensing tube of the portable gas analyzer to the GCS line.

B. Make sure that both valve (59) and the valve in the hydrogen cabinet connected to the GCS line are
closed.

C. Open valve (63) to inspect tightness of valves that were closed in Step B.

D. Crack valve (59) to permit a small amount of pure hydrogen to enter the gas analyzer. Then calibrate
the gas analyzer to measure the percentage of hydrogen in carbon dioxide.

E. After the gas analyzer is calibrated, close valve (59, 63) and also the valve in the hydrogen cabinet.

F. Adjust all the valves as shown in the illustration of Valving Operation for Charging with Hydrogen.
Make sure that all the valves between the generator carbon dioxide distribution pipe and the vent are
open.

G. Connect sensing line of the portable gas analyzer to the GSS line.

H. Admit hydrogen to the top of the generator casing through the hydrogen distribution pipe to force the
carbon dioxide air mixture out of the casing through the carbon dioxide distribution pipe and the GCO
line.I.

J. Admit hydrogen into the generator casing through the GHF line and the hydrogen distribution pipe while
holding the pressure in the generator casing to between 2 and 5 psig [14 to 34 kPa (gauge)] [ 141 to 352
g/cm2 (gauge)] by adjustment of the bottle regulator. An average of about ten minutes is required for
discharging a 200 cubic feet [5.7 m3] bottle of hydrogen into the generator casing. Make sure that valve
(58) is closed so that all the hydrogen is directed into the generator casing.

K. Discharge the hydrogen into the casing until the gas analyzer shows a mixture of 90% hydrogen in the
carbon dioxide being forced from the generator. The amount of hydrogen required to produce a 90%
concentration in the generator casing is approximately 1.75x the casing volume at 0.5 psig [3.4 kPa
(gauge)] [ 35 g/cm2 (gauge)] casing gas pressure.

GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354
 e BEARING
LAB: Gas ManifoldHydrogen Gas
CO2 or Air System
Purge
for
Hydrogen Cooled Generator
VENT HOUSING GENERATOR
FLOW (CO2 or Air In)
METER (#1) 3-Way Valves look like this when...
H2 DIST. PIPE P_ _ _ _ _ _ A _ _ with _ _ 2
TURBINE END COLLECTOR END -OR-
GAS GAS P _ _ _ _ _ _ _ _ with _ _ _ .
ANALYZER ANALYZER
SCAVENGING LINE
FLOW FLOW
METER METER CO2 DIST. PIPE SEAL(#2) When Purging Air with CO2 one of the critical
DRAIN
pressure controls valves is the _ _ _ _ V _ _ _.
ENLARGEMENT
BEARING DRAIN
Next use GEK-103763...
FLOAT TRAP
FILTER FILTER (#3) Before loading H2 we must obtain
DESICANT DESICANT less than _ _ % Air-in- _ _ _ .
HIGH
OIL LEVEL
(#4) When purging H2 with CO2 we should obtain
ALARM
less than __ % _ _ -in- _ _ _

MACHINE DIFF. FAN

PRESSURE PRESSURE AIR TEST/
ROOF PURGE
VENT D___ I___________
A___ Supply

H2 Regulator

SPOOL REGULATOR SPOOL

PIECE PIECE
CORE
(#5) Operators must _ _ _ _ _ _ _ _ position both
MONITOR
H2 Valve3-Way Purge Valves.
Handles Point CO2

(#6) Operators mustDOWN

_ _ _ _ _ _ _ _ position/instruct the
when admitting
"Gas Analyzers"CO2 or Air
to monitor...
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DRYER

CO2INNORMrev1
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ST-GT_LabGenPurge_01-14
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GE Energy Learning Center
 e Hydrogen
LAB: Gas Manifold Normal Gas System
MW Production
for
BEARING
Hydrogen Cooled Generator
VENT HOUSING GENERATOR
FLOW
METER (#1) During normal MW production H2 pressure is
H2 DIST. PIPE managed by __ __ __ - __ __ __ __.
TURBINE END COLLECTOR END
GAS GAS
ANALYZER ANALYZER (#2) During normal MW production the Gas
Analyzer
SCAVENGING LINE monitors
Analyzers monitor __ __ --in-- __ __ __
FLOW FLOW % purity at three (3) places...
METER METER CO2 DIST. PIPE SEAL DRAIN
ENLARGEMENT
(A)_____________________________________
BEARING DRAIN
(B)_____________________________________
FLOAT TRAP
FILTER FILTER (C)_____________________________________
DESICANT DESICANT
HIGH
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OIL LEVEL
Cabinet when it is time to shift the sample location.
ALARM
TE Scavenging Line
CE Scavenging Line (#4) Operators can always see both the real time
MACHINE DIFF. FAN purity as well as the last sample point
PRESSURE PRESSURE at the __ __AIR
__ __ - __ __ __.
TEST/
ROOF PURGE
VENT ?? Device Tag ?? (#5) In the event of LOW-LOW Purity the
__ __ __ - __ __ __ __ recommendation is to....
__ __ __ __ - __ __ __ __ M __ __ __ __ __ __ __ -STOP-
MW production and execute an RCA.
PCV-2935

SPOOL REGULATOR SPOOL

PIECE PIECE
CORE
MONITOR
H2 Valve Handles Point CO2

RIGHT
H2 Make-Up
GAS when admitting H2
DRYER
"Scavenged" H2

STF 11–26A 3/98

ST-GT_LabNormOpH2inAir_01-14 GE Energy Learning Center
LABGCVNORMALr4-12
DWG Number 232D8994 Rev - Released 7/18/2013 Page 1 of 2

       
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DWG Number 232D8994 Rev - Released 7/18/2013 Page 2 of 2

       

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DWG Number 425A5454 Rev - Released 7/30/2013 Page 1 of 28

Dual Hydrogen Control Panel (DHCP)

Software Version 2.2F
HA0385G03

G2E0 28

T.A.GIMINIANI
SENTHIL. P
13-07-25
13-07-25
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Table of Contents
System Operation .......................................................................................................... 7
DHCP Initialization ..................................................................................................... 7
DHCP Menu Displays ................................................................................................... 8
Navigating the LCD Display........................................................................................ 8
LCD Display Menu – Two Modes of Operation .......................................................... 8
Menu Profile ............................................................................................................... 8
Menu Navigation Tutorial............................................................................................. 9
Activating the Menu .................................................................................................... 9
Navigating the Menu in Scrolling Mode (Default) ....................................................... 9
Disabling Scrolling Mode ............................................................................................ 9
Navigating the Menu in Non-Scrolling Mode .............................................................. 9
Function (FN) Menu .................................................................................................. 11
Purge Menu ............................................................................................................... 11
Log Menu .................................................................................................................. 11
Setup Menu ............................................................................................................... 12
Test Menu ................................................................................................................. 12
View Menu ................................................................................................................ 13
Procedures ................................................................................................................... 13
Setting the Alarm Level ............................................................................................. 14
Setting the Warning Level ......................................................................................... 14
Gas Calibration.......................................................................................................... 14
Hydrogen Calibration ................................................................................................ 14
Carbon Dioxide Calibration ....................................................................................... 15
Nitrogen Calibration .................................................................................................. 16
About the Faults Log ................................................................................................. 16
About the Power Log................................................................................................. 17
About the Event Log ................................................................................................. 17
Remote Access .......................................................................................................... 17
Modes of Operation ..................................................................................................... 20
Startup ....................................................................................................................... 20
Startup Problems ....................................................................................................... 20
Suspended Operation ................................................................................................. 20
Purge Operation — H2 in CO2 ................................................................................. 21
Purge Operation – Air in CO2 .................................................................................. 21
Normal Operation ...................................................................................................... 21
Troubleshooting Guide................................................................................................ 21
Design Notes ................................................................................................................ 25

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Figures
Table 1 (Customer Contacts) ......................................................................................... 21
Table 2 (Display Indicators) .......................................................................................... 22
Table 3 (Display Keys) .................................................................................................. 22
Table 4 (GGA Status) .................................................................................................... 23
Table 5 (Relay Problems) .............................................................................................. 23
Table 6 (Events) ............................................................................................................ 24
Revision History............................................................................................................ 25

Copyright 2012 Environment One Corporation

This document contains proprietary information of Environment One Corporation and
may not be used or disclosed to others, except with the written permission of
Environment One Corporation. The transfer, shipment, or communication of any
technology, technical data, software source code, equipment, commodities, or other
products or items that are subject to U.S. Foreign Trade Controls in any manner or
through any means contrary to U.S. Foreign Trade Controls is strictly prohibited.

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System Operation
The DHCP’s main purpose is to analyze and display the hydrogen purity of hydrogen
cooled generators. This section describes system operation.

DHCP Initialization
Apply system power to the DHCP. The GGA DISPLAY PANEL will respond with (a) all
discrete LED’s lit; (b) all segments and the tenths place decimal point of the seven
segment LED displays lit; and (c) all pixels of the LCD display on.
Once communication has been established with the rest of the system, (a) all discrete
LED’s, except the AC POWER and TROUBLE, will turn off; (b) all segments of the seven
segment LED displays will turn off; and (c) the display will echo the results of cold start
initialization:
• GGA Ver 2.2F-7
• CHECKSUM OK
• POWER OK
• I/O BOARD OK
• RELAY TEST …
• … PASSED
• 12BIT ADC TEST
• … PASSED
• Tcell = XX.X°C (where XX.X is the instantaneous cell b lock temperature). For an
indeterminate period (normally not exceeding 15 minutes for a cold start), the LCD will
display the real-time temperature of the sensor cell block. When the temperature rises
to the cell calibration temperature (65°C), the system will advance and the display will
indicate:
• NORMAL (H2/AIR), CONFIGURE VALVES. In response to this prompt, permit the
sample gas to flow through the sensor then press the ENTER key. This is the
NORMAL mode of operation. See Normal for more information.
For a first time installation, it is essential that a gas sensor calibration be performed on
the system. Also, the faults log should be cleared. See Calibration under the Setup
Menu and Clear Faults Log under Log Menu for specific information.

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DHCP Menu Displays

The following sections provide definitions and user information regarding the various
menus that are accessible via the DHCP’s LCD display. It is strongly recommended that
users familiarize themselves with this section. Additional questions can be forwarded to
Environment One Corporation.

Navigating the LCD Display

Four keys control menu operation: FN, ENTER, UP ARROW and DOWN ARROW.
• The FN key activates the menu and exits the menu.
• The ENTER key selects an item from the menu.
• The UP ARROW and DOWN ARROW keys change the selection displayed.

LCD Display Menu – Two Modes of Operation

The menu has two modes of operation, scrolling and non-scrolling.
• In scrolling mode, the selection shown on the LCD changes automatically every two
seconds.
• In non-scrolling mode, the UP ARROW and DOWN ARROW keys must be used to
change the selection.
Scrolling is the default mode. Users can change modes by reviewing the SETUP MENU
section in the following pages.

Menu Profile
Six menus are available: Function, Log, Purge, Setup, Test and View. The Function
menu is the top-level menu; all other menus are accessed through this menu.

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Menu Navigation Tutorial

Activating the Menu
1. Press FN to start the menu. The LCD should display the prompt <FUNCTION
MENU>.
2. Press FN again to turn it off.

Navigating the Menu in Scrolling Mode (Default)

1. Press FN to start the menu. The LCD should display the prompt <FUNCTION
MENU>. After two seconds the prompt should change to GO TO LOG MENU.
2. Wait until the prompt GO TO LOG MENU appears and press the ENTER key.
3. The LCD should display the prompt <LOG MENU>.
4. Wait until the prompt SHOW PROGRAM ID appears and press the ENTER key.
The display should show GGA VER 2.2F-7.
5. Press the FN key. The prompt will be restored to SHOW PROGRAM ID.
6. Press FN again. The prompt will be restored to GO TO LOG MENU.
7. Press FN a third time. The LCD will display “GGA by E/One” as the menu is
deactivated.

Disabling Scrolling Mode

1. Press FN to start the menu.
2. Wait until the prompt GO TO SETUP MENU appears and press ENTER.
3. Wait until the prompt SET SCROLL OFF appears and press ENTER.
4. The prompt will flash SET SCROLL OFF.
5. Press FN to return to the beginning of the menu.

Navigating the Menu in Non-Scrolling Mode

1. The LCD should display the prompt <FUNCTION MENU>. Press the DOWN
ARROW key until the prompt GO TO LOG MENU appears and press the ENTER
key.
2. The LCD should display the prompt <LOG MENU>. Press the DOWN ARROW
key until the prompt SHOW PROGRAM ID appears and press the ENTER key.
The display should show GGA VER 2.2F-7.
3. Press the FN key. The prompt will be restored to SHOW PROGRAM ID.
4. Press FN again. The prompt will be restored to GO TO LOG MENU.

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Function (FN) Menu

• GO TO LOG MENU Select this item to enter the LOG MENU. The log menu contains
selections to view and clear the fault and power logs. The log menu also includes a
selection to view the software version number.
• GO TO PURGE MENU Select this item to enter the PURGE MENU. The Purge Menu
includes selections to change to a different range for purge operations. The available
alternate ranges are hydrogen in carbon dioxide and air in carbon dioxide.
• GO TO SETUP MENU Select this item to enter the SETUP MENU. The Setup Menu
includes selections for calibration and configuration. Items that an be configured
include the Warning level, Alarm level, operating mode and menu scroll rate. The
Setup menu also includes selections to calibrate the reference values for hydrogen,
nitrogen and carbon dioxide.
• GO TO TEST MENU Select this item to enter the TEST MENU. The test menu
contains selections to test the power supplies, the keypad, the relays, and the 4-20 mA
outputs.
• GO TO VIEW MENU Select this item to enter the View Menu. The View Menu contains
selections to view the calibration constants, cell temperature, thermistor voltages, A/D
converter voltages and internal registers.

Purge Menu
• PURGE (H2/ CO2) Select this item to change the range from hydrogen in air to
hydrogen in carbon dioxide. See Purge Operation for more information.
• PURGE (AIR/CO2) Select this item to change the range from hydrogen in air to air in
carbon dioxide. See Purge Operation for more information.

Log Menu
• SHOW FAULTS LOG Select this item to view the faults log. See About the Fault Log
for more information.
• CLEAR FAULTS LOG Select this item to clear the faults log. When selected, the
CLEAR FAULTS LOG prompt will flash for two seconds before clearing the faults log.
If the FN key is pressed while it is still flashing, clearing of the log will be canceled. See
About the Fault Log for more information.
• SHOW POWER LOG Select this item to view the power log. See About the Power Log
for more information.
• CLEAR POWER LOG Select this item to clear the power log. When selected, the
CLEAR POWER LOG prompt will flash for two seconds before clearing the power log.
If the FN key is pressed while it is still flashing, clearing of the log will be canceled. See
About the Power Log for more information.
• SHOW EVENT LOG Select this item to view the events log. See About the Event Log
for more information.

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• SHOW PROGRAM ID Select this item to display the program identification and revision
level in the format GGA Rev. X.X. This manual was written for software version2.2F.
Press the UP arrow key to access additional version information. The next prompt
gives the I/O board version in the format I/O VERSION X.XX. The last prompt gives
the controller board part number in the format PROC=XXXXXXGXX. This manual was
written for controller board P/N HA0385G0. Press the FN key to return to the LOG
MENU.

Setup Menu
• GAS CALIBRATION Select this item to calibrate the GGA with hydrogen, nitrogen or
carbon dioxide gas. See Gas Calibration for more information.
• PURITY COMP Select this item to enter a cell compensation value.
• WARNING LEVEL Select this item to change the warning level. See Setting the
Warning Level for more information.
• ALARM LEVEL Select this item to change the alarm level. See Setting the Alarm Level
for more information.
• ADVANCED Select this item to setup the GGA for remote access. See Remote Access
for more information.
• STOP MONITORING This item is to be used for troubleshooting and is displayed when
the monitoring is turned on. Select this item to turn off monitoring. When selected, the
STOP MONITORING prompt will flash STOPPING for two seconds before monitoring
is suspended. If the FN key is pressed while it is flashing, the command will be
canceled. See Suspended Operation for more information.
• START MONITORING This item is displayed when the monitoring has been
suspended. Select this item to turn monitoring on. When selected, the START
MONITORING prompt will flash STARTING for two seconds before monitoring begins.
If the FN key is pressed while the prompt is flashing, the command will be canceled.
See Normal Operation for more information.
• SET SCROLL OFF This item is displayed when the scrolling is turned on. Select this
item to turn off scrolling. When scrolling is inactive, the displayed menu items will not
change until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed.
• SET SCROLL ON This item is displayed when the scrolling is turned off. Select this
item to turn on scrolling. When scrolling is active, the displayed menu items will
change once every two seconds.

Test Menu
• CONTACT TEST Select this item to start an interactive test of the relay contacts. The
GGA will place all relays except one in a de-energized condition. The LCD will display
the name of the single relay that is still energized. Use the arrow keys to change which
relay is energized. Press the FN or ENTER keys to terminate the test.
• KEYPAD TEST Select this item to start an interactive test of the keypad. The LCD will
display the prompt PRESS ANY KEY at the start of the test. Test the keypad by
pressing, one at a time, all of the keys on the keypad,

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reserving the FN key for last. The LCD will echo the name of each key as it is pressed.
The test will terminate when the FN key is pressed.
• OUTPUT TEST Select this item to start an interactive test of the 4 to 20 mA outputs.
The GGA will clear the numeric displays, set the 4-20 mA outputs to 4 mA and display
CURRENT=4 mA on the LCD display at the start of the test. Use the arrow keys to
increase or decrease the current in 1 mA steps. Press FN or ENTER to terminate the
test.
• POWER TEST Select this item to test the power supplies. When Power Test is
selected, the GGA will display the voltage for each power supply in the format
<nominal value>=<present value>. An example of the 12-volt power supply is +12
VOLTS=12.1. The GGA will scroll through all five power supply voltages. The voltages
are displayed for two seconds each.
• RELAY TEST Select this item to test all of the relays. The LCD will display RELAY
TEST… The system will cause each relay to be energized. If no errors are detected,
the LCD will display RELAYS PASS. If an error is detected, the LCD will display the
failure mode and then list the names of the malfunctioning relays. The failure modes
are STUCK ON and STUCK OFF. Refer to Table 5 for a list of the probable cause(s)
of the error(s).

View Menu
• VIEW CALIBRATION Select this item to display the calibration values for the sensor
cell. The format for the first four displayed values is “Vnn=X.XXX VDC” where Vnn is
the symbol and X.XXX is the voltage of a calibration constant. The symbols for the four
calibration constants are: Vref for the reference thermistor; Vn2 for nitrogen gas; Vh2
for hydrogen gas; and Vco2 for carbon dioxide. Use the UP ARROW key or DOWN
ARROW key to scroll through the calibration constants. Press the FN key to return to
the VIEW MENU.

• VIEW TCELL Select this item to view the cell temperature in real time. The
temperature is displayed in the format Tcell=XX.XC where XX.X is the temperature in
degrees centigrade.
• VIEW CELL VOLTS Select this item to view the thermistor voltages in real time. The
voltages are displayed in the format s=X.XXX r=X.XXX where s stands for the sample
thermistor and r stands for the current value of the reference thermistor voltage.
• VIEW 12BIT ADC Select this item to display the voltage at each of the four inputs to
the 12-bit A/D converter. Use the UP ARROW or DOWN ARROW to scroll through all
four channels. Press the FN key to return to the View Menu.
• VIEW REGISTER Select this item to display the values in the internal registers. Use
the UP ARROW to view the next register or the DOWN ARROW to view the previous
one. Press the FN key to return to the View Menu.

Procedures

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Setting the Alarm Level

The alarm level determines what ratio of hydrogen to air will trigger an Alarm indication.
The alarm level is expressed as a percent. An Alarm indication is given when the purity
drops below the value of the alarm level and remains there for at least one minute after a
Warning is indicated. An Alarm will only occur if the GGA is in Normal mode. The factory
default value for the alarm level is 85 percent. The Alarm level can be changed by
selecting ALARM LEVEL from the Setup Menu.
When ALARM LEVEL is selected, the Alarm level will be displayed on the LCD display.
Press the UP ARROW to increase the level; press the DOWN ARROW to decrease the
level. The level cannot be increased beyond the Warning level or decreased below 80
percent. Press the ENTER key to save your changes and return to the Setup Menu.
Press the FN key to discard changes and return to the Setup Menu.

Setting the Warning Level

The warning level determines what ratio of hydrogen to air will trigger a WARNING
indication. The warning level is expressed in percent. A WARNING indication is given
when the purity drops below the value of Warning level and remains there for at least
one minute. A WARNING will only occur if the GGA is in normal mode. The factory
default value for the Warning level is 90 percent. The Warning level can be changed by
selecting WARNING LEVEL from the Setup Menu.
When WARNING LEVEL is selected, the Warning level will be displayed on the LCD
display. Press the UP ARROW key to increase the level; press the DOWN ARROW key
to decrease the level. The Warning level cannot be increased beyond 99 percent or
decreased below the Alarm level. Press the ENTER key to save your changes and
return to the SETUP MENU. Press the FN key to discard the changes and return to the
SETUP MENU.

Gas Calibration
Calibrate each of the two gas analyzer units separately.
Select the GAS CALIBRATION option on the SETUP menu to begin gas calibration.
There are three operations available through the GAS CALIBRATION SETUP menu.
The operations are:
• CALIBRATE H2 Select this item to calibrate the GGA with 100 percent hydrogen gas.
• CALIBRATE CO2 Select this item to calibrate the GGA with 100 percent carbon
dioxide gas.
• CALIBRATE N2 Select this item to calibrate the GGA with 100 percent nitrogen gas.

Hydrogen Calibration

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1. Begin hydrogen gas calibration by selecting CALIBRATE H2 from the Setup

Menu.
2. In response to the prompts CALIBRATE H2, CONFIGURE VALVES, permit the
hydrogen calibration gas to flow through the sensor.
3. The LCD will display the voltage output of the reference cell sensor in the
format Vref=X.XXX VDC. Press the FN key to cancel the calibration at this point,
if desired; this will permit a return to the main menu. If desired to continue the
calibration, observe the reference voltage and, if it appears stable press the
ENTER key.
4. The LCD will display the voltage output of the sample cell sensor in the format
“Vcell=X.XXXVDC.” Again, the calibration may be terminated by pressing FN. If it
is continued, observe the sample cell voltage as it adjusts to the flowing H2
calibration span gas. When it appears stable (approximately 15 minutes) press
the ENTER key. The LCD will display H2 CALIBRATED. This concludes H2
calibration.
The cell voltage for hydrogen gas should range between 2.5 and 4.095 volts. The LCD
will flash INVALID for two seconds and refuse to accept the calibration value if the
voltage is outside of this range. Verify that the calibration gas is hydrogen if the value is
2.5 volts or below. Troubleshoot the electronics if the value is 4.095 or above.
The display will scroll the prompts CALIBRATE H2, CALIBRATE CO2 and CALIBRATE
N2. Press the Fn key on the GGA to return to the main menu or wait until the display
scrolls to the prompt CALIBRATE CO2 and press the ENTER key to continue gas
calibration.

Carbon Dioxide Calibration

1. Begin carbon dioxide gas calibration by selecting CALIBRATE CO2 from the
Setup Menu.
2. In response to the prompts CALIBRATE CO2, CONFIGURE VALVES, permit the
CO2 calibration gas to flow through the sensor.
3. The LCD will display the voltage output of the reference cell sensor in the format
Vref=X.XXX VDC. Press the FN key to cancel the calibration at this point, if
desired; this will permit a return to the main menu. If desired to continue the
calibration, observe the reference voltage and, if it appears stable press the
ENTER key.
4. The LCD will display the voltage output of the sample cell sensor in the format
Vcell=X.XXX VDC. Again, the calibration may be terminated by pressing FN. If it
is continued, observe the sample voltage as it adjusts to the flowing CO2
calibration zero gas. When it appears stable (approximately 15 minutes), press
the ENTER key. The LCD will display CO2 CALIBRATED. This concludes CO2
calibration.
The cell voltage for carbon dioxide gas should range between 1.0 and 2.5 volts. The
LCD will flash INVALID for two seconds and refuse to accept the calibration value if the
voltage is outside of this range. Verify that the calibration gas is carbon dioxide if the

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value is 2.5 volts or above. Troubleshoot the electronics if the value is less than 1.001
volts or greater than 4.094 volts.
The display will scroll the prompts CALIBRATE H2, CALIBRATE CO2 and CALIBRATE
N2. Press the Fn key on the GGA to return to the main menu or wait until the display
scrolls to the prompt CALIBRATE N2 and press the ENTER key to continue gas
calibration.

Nitrogen Calibration
1. Begin nitrogen gas calibration by selecting CALIBRATE N2 from the SETUP
MENU.
2. In response to the prompts CALIBRATE N2, CONFIGURE VALVES, permit the
nitrogen calibration gas to flow through the sensor.
3. The LCD will display the voltage output of the reference cell sensor in the
format Vref=X.XXX VDC. Press the FN key to cancel the calibration at this point,
if desired; this will permit a return to the main menu. If desired to continue the
calibration, observe the reference voltage and, if it appears stable press the
ENTER key.
4. The LCD will display the voltage output of the sample cell sensor in the format
Vcell=X.XXX VDC. Again, the calibration may be terminated by pressing Fn. If it
is continued, observe the sample voltage as it adjusts to the flowing N2 calibration
zero/span gas. When it appears stable (approximately 15 minutes) press the
ENTER key. The LCD will display N2 CALIBRATED. This concludes N2
calibration.
The cell voltage for nitrogen gas should range between 1.0 and 2.5 volts. The LCD will
flash INVALID for two seconds and refuse to accept the calibration value if the voltage is
outside of this range. Verify that the calibration gas is nitrogen if the value is 2.5 volts or
above. Troubleshoot the electronics if the value is less than 1.001volts or greater than
4.094 volts.
Press the Fn key to return to the main menu. This concludes the gas sensor calibration
of the GGA system.

About the Faults Log

The Faults log traps these error conditions: I/O Fault, COMM Fault, TCELL Fault, CAL
Fault and Power Fault.
• An I/O Fault is logged when a communication error is detected in the communication
channel that connects the processor with the relay outputs.
• A COMM Fault is logged when a communication error is detected in the
communication channel that connects the processor to the Display or I/O board.
• A Tcell Fault is logged when the temperature of the sensor cell drifts out of
specification during normal operating mode.

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• A Power Fault is logged when the measured voltage of one or more of the power
supplies is out of specification.
• A 12 BIT ADC FAULT is logged when the 12 bit ADC converter fails calibration on the
first attempt.
• A Cal Fault is logged when one of the following conditions occurs:
a) The Hydrogen calibration value is less than two and a half volts or greater than
four point zero nine four volts.
b) The Nitrogen calibration value is less than one volt or greater than two and a half
volts.
c) The real time cell voltage is at least three percent above the hydrogen calibration
value and the analyzer is in normal mode.
d) The real time cell voltage is at least three percent below the nitrogen calibration
value and the analyzer is in normal mode.

About the Power Log

The Power log records the minimum and maximum voltage of each power supply. The
voltage is sampled once every two seconds.
When SHOW POWER LOG is selected, the GGA will display the minimum and
maximum for each power supply in the format <nominal value>=<minimum value>,
<maximum value>. An example for the 12-volt power supply is +12V=11.8,12.1. Use the
UP ARROW key or DOWN ARROW key to scroll through the five power supply voltages.
Press the FN key to return to the LOG MENU.

About the Event Log

The Event log records the date and time of significant operational events. The events
are stored in a circular queue holding the last two hundred events. The oldest event is
overwritten each time a new event is recorded. The list of possible events is contained in
Table 6.
The most recent event is displayed when SHOW EVENT LOG is selected. Press the
ENTER key to display the date and time of the event. Press the DOWN ARROW key to
display the previous event. Press the UP ARROW key to display the next event. (The
display will wrap around to the oldest event if the UP ARROW key is pressed while
displaying the most recent event).

Remote Access
The GGA can be controlled from the local display located on the front of the instrument
or from a remote display located in the control room or some other convenient location.
Control can be transferred from the local to the remote display using the keypad. First
press the FN key. The instrument will respond with a password request. Enter the four
digit password by pressing the up arrow key to increase the lowest digit and the down
arrow to shift the number to the left. (for example press the up arrow once, the down
arrow once, the up arrow twice, the down arrow once, and the

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up arrow three times to enter the password 123). Press enter; the instrument will
respond with the word “ACCEPTED”. You now have control of the instrument.
Settings for remote operation can be reached by selecting the ADVANCED option on the
SETUP MENU. There are eight options available in the ADVANCED SETUP menu. The
options are:
• SET PASSWORD: Select this item to change the remote access password.
• SET ADDRESS: Select this item to change the instrument remote access address.
• SET BAUD RATE: Select this item to change the I/O board serial port communication
speed.
• SET DATE/TIME: Select this item to set the date and time.
• LOCK FILE SYSTEM: Select this item to lock the file system in preparation for
changing the data recording media.
• FORMAT ALL FILES: Select this item to initialize the file system to the factory
defaults.
• RESET REMOTE: Select this item to initialize the remote serial port to the factory
defaults.
• RESET I/O: Select this item to reset the I/O board.
When SET PASSWORD is selected, “0000” will be displayed on the LCD display. (The
current password is not displayed). Enter a four digit password by pressing the UP
ARROW key to increase the lowest digit and the DOWN ARROW to shift the number to
the left. (for example press the UP ARROW once, the DOWN ARROW once, the UP
ARROW twice, the DOWN ARROW once, and the UP ARROW three times to enter the
password 123). Press the ENTER key to save the password and return to the Advanced
Menu. Press the FN key to leave the original password unchanged and return to the
Advanced Menu.
When SET ADDRESS is selected, the current address will be displayed on the LCD
display. Press the UP ARROW to increase the address; press the DOWN ARROW to
decrease it. Press the ENTER key to save your changes and return to the Advanced
Menu. Press the FN key to discard changes and return to the Advanced Menu.
When SET BAUD RATE is selected, the baud rate will be displayed on the LCD display.
Three baud rates are available: 2400, 9600 and 38,400 baud. Press the UP ARROW to
increase baud rate; press the DOWN ARROW to decrease it. Press the ENTER key to
save your changes and return to the Advanced Menu. Press the FN key to discard
changes and return to the Advanced Menu.
The following three selections affect the onboard file system. The onboard file system
used to save historical data. The fault log, the event log and trending data is stored in
the file system. The three selections allow the file system to be stopped, started and
initialized.
When SET DATE/TIME is selected, the date will be displayed on the LCD display. The
date and time has six settable fields: the year, month, day, hour, minute and second.
The selected field will flash. Press the ENTER key to advance to the next field. Press the
FN key to return to the previous field. Press the UP ARROW
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to increment the field; press the DOWN ARROW to decrement it. Press the ENTER key
with the second field flashing to save your changes and return to the Advanced Menu.
Press the FN key with the year field flashing to discard your changes and return to the
Advanced Menu.
When LOCK FILE SYSTEM is selected, the current state of the file system lock will be
displayed on the LCD display. Press the UP ARROW to turn the lock on; press the
DOWN ARROW to turn it off. Press the ENTER key to save your changes and return to
the Advanced Menu. Press the FN key to discard changes and return to the Advanced
Menu.
When FORMAT ALL FILES is selected, the file system definition will be reset to the
factory defaults. The file system must be locked before selecting this option or the format
will be cancelled. Once complete the format cannot be undone. The file system must be
unlocked or the GGA restarted after the format is complete.
The remote access port is optional. An instrument address of 255 will be displayed if the
port is not available.
The I/O board serial port is optional. A baud rate of 1800 will be displayed if the I/O
board does not support serial communication.
The GGA display communicates at 9600 baud. A special display will be required to
communicate at one of the optional baud rates.

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Modes of Operation
Startup
The GGA initializes all relays to the de-energized position.
The GGA executes a “power on self-test” (POST) to verify its proper operation. It verifies
its software by checksum testing the contents of its read-only memory (ROM). It tests all
of its power supplies and all of its relays. It checks the cell temperature and waits until it
reaches normal operating temperature (55°C or 65°C).
The POST will take about 20 seconds to complete if no errors are encountered and the
cell is at its normal operating temperature. At the conclusion of the POST the GGA will
flash NORMAL (H2/AIR), CONFIGURE VALVES. Verify the valve configuration and then
press the ENTER key for normal operation or the FN key for suspended operation.

Startup Problems
The GGA verifies its software by checksum testing the contents of its read-only memory
(ROM). If it finds a problem it will stop the POST process and flash BAD CHECKSUM on
the LCD. The FN key may be pressed to allow the GGA to continue the POST process.
However, proper operation cannot be guaranteed if this error is present.
The GGA will annunciate any problems it finds with the power supplies, I/O board or
relays. The presence of one or more of these faults will not stop the POST process.
However, they should be corrected as soon as possible because they indicate a
hardware problem.
The GGA tests the 12-bit A/D converter responsible for measuring the cell voltages. If it
cannot communicate with the A/D converter, the display will flash 12BIT ADC FAILED.
The FN key may be pressed to allow the GGA to continue the POST process. However,
proper operation of the A/D converter should be verified.
The GGA examines the cell voltages and compares them to expected values. An
improperly connected cell, a defective cell cable or a problem with the cell itself can
result in voltages outside of the expected range. If the GGA detects any voltages outside
of their expected range, the display will flash CELL PROBLEM. The FN key may be
pressed to allow the GGA to continue the POST process. However, proper operation
of the sensor cell must be verified.
The GGA requires that the cell come within 3°C of i ts normal operating temperature
(55°C or 65°C) before enabling NORMAL OPERATION. Th e POST will wait until the cell
temperature falls within this range before proceeding. The test can be bypassed by
pressing the ENTER key.

Suspended Operation
When the GGA is in suspended operation it will not monitor the gas concentration or
generate any alarms or warnings. The Trouble LED will be illuminated whenever the
GGA is in this mode of operation. The numerical displays will be blank and the 4-20 mA
output will indicate zero percent gas purity.

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Purge Operation — H2 in CO2

When the GGA is in purge hydrogen in carbon dioxide operation it will display the
concentration of hydrogen in CO2. It will not generate any alarms or warnings. The GGA
will display the measured purity on the numerical displays. The measured purity is also
available through a 4-20 mA output. The 4-20 mA current output of the GGA
corresponds to 0 to 100 percent gas purity.

Purge Operation – Air in CO2

When the GGA is in “purge air in carbon dioxide” operation it will display the
concentration of air in CO2. It will not generate any alarms or warnings. The GGA will
display the measured purity on the numerical displays. The measured purity is also
available through a 4-20mA output. The 4-20 mA current output of the GGA corresponds
to 0 to 100 percent gas purity.

Normal Operation
Note: It is important to verify that the lines connecting LE025 to the turbine-end seal
drain enlargement, LE026 to the collector-end seal oil enlargement, and LE028 to the
case fan pressure are filled with hydrogen before placing the system into Normal
operation.
When the GGA is in Normal operation it will display the concentration of the hydrogen in
air. It will indicate a warning or alarm condition if it is out of specification. The GGA
monitors the gas purity with a thermal conductivity cell. The GGA will display the
measured purity on the numerical displays. The measured purity is also available
through a 4-20 mA output. The 4-20 mA current output of the GGA corresponds to 70 to
100 percent gas purity.

Troubleshooting Guide
Table 1 (Customer Contacts)
Contact Status Ref. 1
ALARM Energized when the GGA is in measuring hydrogen 1
General Purpose in air and the concentration is below the alarm level.
WARNING Energized when the GGA is in measuring hydrogen 2
General Purpose in air and the concentration is below the warning
TROUBLE De-energized when the GGA detects an abnormal 3,4,5
General Purpose condition.
NORMAL Energized when the GGA is measuring the
General Purpose concentration of hydrogen in air.

1
See Table 4 (DHCP Status)
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Table 2 (Display Indicators)

Indicator Status Ref. 2
AC POWER Lit when the display panel is powered and
functioning properly
NORMAL Lit when the GGA is measuring the concentration
of hydrogen in air.
ALARM Lit when the GGA is in measuring hydrogen in air 1
and the concentration is below the alarm level.
WARNING Lit when the GGA is in measuring hydrogen in air 2
and the concentration is below the warning level.
TROUBLE Lit when the GGA detects an abnormal condition. 3,4,5

CALIBRATE H2 Lit when the GGA is being calibrating against a

100% hydrogen standard.
CALIBRATE CO2 Lit when the GGA is being calibrating against a
100% carbon dioxide standard.
CALIBRATE N2 Lit when the GGA is being calibrating against a
100% nitrogen standard.
PURGE H2 in CO2 Lit when the GGA is measuring the concentration
of hydrogen in carbon dioxide.
PURGE AIR in CO2 Lit when the GGA is measuring the concentration
of air in carbon dioxide.
GAS PURITY Three digit gas purity indicator (0 to 99.9%).

LCD Display Displays the current menu selection when the

menu is active.

Table 3 (Display Keys)

Key Function
Reset Clear the Alarm and Warning conditions in normal
mode
Fn Activate the menu

ENTER Select a menu item

UP ARROW Used with some menu options to increase the value

of a constant.
DOWN ARROW Used with some menu options to decrease the
value of a constant.

2
See Table 4 (DHCP Status)
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Table 4 (DHCP Status)

Condition Typical Cause Indicators Effected
1 Alarm The GGA is in measuring ALARM LED + ALARM
hydrogen in air and the RELAY
concentration is below the alarm
level
2 Warning The GGA is in measuring WARNING LED +
hydrogen in air and the WARNING RELAY
concentration is below the
warning level
3 Tcell Error The sensor cell is not within TROUBLE LED
±5.0°C of its normal operating + TROUBLE RELAY
temperature (55°C or 65°C).
4 Power Supply One or more power supplies are TROUBLE LED
Problem3 not within tolerance. + TROUBLE RELAY
5 I/O Error 4 The GGA is detecting a TROUBLE LED
communication error while trying + TROUBLE RELAY
to talk to the I/O board or the
display. One or more relays are
defective.
6 Relay Error 4 One or more relays are defective. TROUBLE LED
+ TROUBLE RELAY

Table 5 (Relay Problems)

STUCK ON STUCK OFF
General Purpose relays: Electronics failure Electronics failure
WARNING RELAY
ALARM RELAY
TROUBLE RELAY
NORMAL RELAY

3
Run power test and examine power log to identify power supply problems.
([DPLQHHUURUORJWRLGHQWLI\ZKLFKHUURULVSUHVHQW

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Table 6 (Events)
EVENT DESCRIPTION
GGA RESET The GGA started operating. Caused by power being applied
or the reset on the back of the display being pressed.
I/O TST PBLM The GGA could not detect that the proper I/O board was
attached.
ADC CAL PBLM The 12 bit analog to digital converter failed calibration.
DC POWER PBLM One or more of the DC power supplies was out of
calibration.
RLY TST PBLM One or more relays failed the relay test.
CALIBRATING The gas calibration process was started.
CALIBRATION QUIT The gas calibration process was stopped before completion
ERASE CALIB INFO All of the gas calibration information was erased.
H2 CALIBRATED Hydrogen calibration completed successfully.
N2 CALIBRATED Nitrogen calibration completed successfully.
CO2 CALIBRATED Carbon dioxide calibration completed successfully.
H2 IN AIR RANGE The Hydrogen in air range was selected.
H2 IN CO2 RANGE The Hydrogen in carbon dioxide range was selected.
AIR IN CO2 RANGE The air in carbon dioxide range was selected.
NOT MONITORING No range was selected
CALIBRATION PBLM A calibration problem was detected.
PURITY ALARM The Hydrogen in air purity alarm was detected.
ALARM RESET The purity alarm was reset.

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Revision History

REV DESCRIPTION Initial Date

- RELEASED PER ECN 12-17957 TJS March 26, 2012
A REVISED PER ECN 12-18727 TJS July 19, 2012
B REVISED PER ECN 12-19090 MMc SEPT 25, 2012
C REVISED PER ECN 13-20470 TAP MAY 10, 2013
Digitally signed by Thomas Parenti

Checked By Thomas Parenti DN: cn=Thomas Parenti, c=US, o=Eone, ou=Usb

Engineering, [email protected]
Date: 2013.05.10 10:42:45 -04'00'

Eng Appv’l
Digitally signed by Ted Shelmerdine

Ted Shelmerdine DN: cn=Ted Shelmerdine, c=US, o=Environment One

Corp., ou=USB, [email protected]
Date: 2013.05.20 09:44:39 -04'00'

Issued By
Digitally signed by Edward Li

Edward Li DN: cn=Edward Li, c=US, o=Environment One,

ou=Engineering, [email protected]
Date: 2013.05.23 17:08:01 -04'00'

Design Notes
Software version 2.2F is a form fit and function replacement for software version 2.2E. It
is upwardly compatible and provides the following enhancements:
• Change allowable range of purity compensation from -2 to +4 to 0 to +5.
Software version 2.2E is a form fit and function replacement for software version 2.2D. It
is upwardly compatible and provides the following enhancements:
• Added EVENT LOG to the LOG menu.
• Selection “Format all Files” added to the advanced menu.
Software version 2.2D is a form fit and function replacement for software version 2.2C. It
is upwardly compatible and provides the following enhancements:
• Selection “Set Date/Time” and “Lock File System” added to the advanced menu.
• Minor updates to the internal data recording system.
Software version 2.2C is a form fit and function replacement for software version 2.2B. It
is upwardly compatible and provides the following enhancements:
• Extensive changes to the internal data recording system.
Software version 2.2B is a form fit and function replacement for software version 2.2A. It
is upwardly compatible and provides the following enhancements:
• Additional remote communication support added.
• Updated the 4-20 milliamp mapping.
• The BURN-IN test was added back.
Software version 2.2A is derived from software version 2.1B. It is upwardly compatible
and provides the following enhancements:
• The BURN-IN test was dropped from the menu.

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A Precision Castparts Company

Environment One Corporation

2773 Balltown Road
Niskayuna, New York USA 12309–1090

Tel: (01) 518.346.6161

Fax: 518.346.6188

www.eone.com

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Tab 24
 GEK 107358
April 2000
Replaces CSFDMKV_VI

GE Power Systems
Gas Turbine

Functional Description

I. GENERAL

Gas turbine control systems include the systems used for modulation and control of fuel input to the gas tur-
bine in normal starting, operating, and loading. They are the speed control, temperature control, startup con-
trol, fuel control and load limit control systems. Other support systems include control devices that also inter-
act with the control systems to ensure continuous reliable operation of the gas turbine.

The turbine/generator control systems consist of the gas-turbine-mounted components and devices, the pan-
el-mounted control circuits, instruments and devices, and interconnecting wiring.

The turbine/generator panel mounted electrical controls are contained in several vertical control panels con-
sisting of:

Turbine control panel

Generator control panel

Motor control center

Human Machine Interface (HMI)

Within the turbine control panel are the SPEEDTRONIC* governor and control circuits. The SPEED-
TRONIC control provides the solid-state analog and digital electronic computing components required
for gas turbine control, protection, and sequence logic systems. The SPEEDTRONIC panel receives speed
and exhaust temperature information from the gas turbine and computes the required or permissible variable
control EMF (FSR) voltage. This FSR voltage is the input signal to the fuel system to obtain or to limit the
required fuel input for starting, synchronizing, operating, and loading of the gas turbine.

The turbine and generator control panels are located in the control compartment. The panels, mounted side
by side in this location, provide for local control of the turbine/generator. Each panel has a hinged front door
to provide accessibility to panel components. Included in the control panels are strip heaters for humidity
and temperature control, as well as lighting and convenience outlets.

* Trademark of the General Electric Company

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 2000 GENERAL ELECTRIC COMPANY
GEK 107358 Functional Description

Motor control center equipment may also be included in the control compartment for the sequencing and
protection of the on-base and off-base motor-driven auxiliaries, or this equipment may be provided as an
off-base packaged electrical control center.

The HMI is a personal computer based operator interface consisting of one or more CRTs, keyboards, etc.,
usually located in the control compartment. One or more MMIs can be located in the customer’s control
room, providing for certain remote control and indicating functions at a central or remote control point.

II. CONTROL PANEL FEATURES AND CONTROLS

A. Turbine Control Panel

The Turbine Control System is designed to fulfill all gas turbine control requirements. These include
control of liquid, gas or both fuels in accordance with the requirements of the speed or load control under
part-load conditions, temperature control under maximum capability conditions, or during start-up
conditions. In addition, inlet guide vanes and water or steam are controlled to meet emissions and operat-
ing requirements. If emissions control utilizes dry low NOx techniques, fuel staging and combustion
mode are controlled by the Turbine Control System which also monitors the process. Sequencing of the
auxiliaries to allow fully automated start-up, shutdown and cool-down are handled by the Turbine Con-
trol System. Turbine protection against adverse operating situations and annunciation of abnormal
conditions are incorporated into the basic system.

The SPEEDTRONIC turbine control system consists of at least one personal computer along with a
free-standing control cabinet. The computer, with its associated color monitor, cursor positioning de-
vice, keyboard and printer, is the operator interface. The control cabinet contains three identical control
microprocessors, a protective module, a power distribution module, and digital/analog input/output
modules.

The SPEEDTRONIC gas turbine control system includes triple redundant microprocessor controllers
with two-out-of-three voting redundancy on critical control and protection parameters. This redundancy
significantly reduces outages caused by control system failures. It also provides for repair and replace-
ment by maintenance personnel without shutting down the gas turbine.

Operator commands are made by using the appropriate cursor positioning device with the monitor. Some
of the displays available to the operator are:

• Main – all normal operating parameters

• Alarm – turbine and driven device alarms

• Diagnostic Alarm – internal diagnostic self-checks and tests

• User Defined – screens custom configured to show temperatures, pressures, flows and other machine
parameters

Two types of alarms (Diagnostic Alarms and Process Alarms) and two types of events (Contact Inputs
and Events) are logged to the printer(s) for historical purposes. Most gas turbine applications will also
log exhaust emissions-related data to the printer(s).

2
Functional Description GEK 107358

The turbine control panel instrumentation and a description of the functions each provides is discussed
in the Operation section of this manual. Component information for the turbine panel devices is included
in this volume under the appropriate tab.

B. Generator Control Panel

The generator control panel is a vertical enclosure that contains generator control equipment, meters,
switches and relays. The synchronizing relays and other generator control and output monitoring de-
vices are required for synchronizing and operation of the generator. The meters, switches and synchro-
nizing relays are front panel mounted devices. These devices and the functions they perform are listed
and defined in the Operation section.

Several other generator relays (such as auxiliary, undervoltage, overcurrent, lockout, differential, etc.)
used in generator protection, control and power distribution circuits are also included in the generator
control panel. These relays are listed in the Table of Contents of this Volume and component information
is included under the tab, Generator Panel Devices.

Synchronizing equipment mounted on this panel includes a two position (automatic/manual) synchro-
nizing selector switch, scope and synchronizing lamps to indicate the phase relationship between the
generator being synchronized and the bus.

C. Motor Control Center (Control Compartment)

The motor control center (MCC) panel, when located in the control compartment, contains ac power
distribution panelboards with associated circuit breakers, lighting transformer, and motor starters for
controlling power to other off-base components, when provided. This panel provides power distribution
for the following functions:

1. Three-phase power distribution.

2. Single-phase power distribution for heating, lighting, air conditioning and compartment conve-
nience outlets.

3. Auxiliary bus undervoltage detection and alarm, and automatic control for switching the emergency
lighting circuit to dc power in the event of normal power failure.

D. Motor Control Center (Packaged Electrical Control Compartment)

The motor control center (MCC), located in the packaged electrical control compartment, consists of sev-
eral bays of starter equipment. The motor control center provides for the following auxiliary functions:

1. Three-phase power distribution for various pumps, fan motors, and heaters.

2. Single-phase power distribution for heating, lighting, air conditioning and compartment conve-
nience outlets.

3. DC power distribution for emergency power to various compartment controls and panel power.

3
GEK 107358 Functional Description

4. DC power distribution for emergency power to various compartment controls and panel power.

5. Auxiliary bus undervoltage detection and alarm, and automatic control for switching the emergency
lighting circuit to dc power in the event of normal power failure.

6. DC motor control for the emergency lube pump.

The motor starters are of the full voltage, non-reversing, three-phase, combination-type construction;
and include an air circuit breaker, contactor, electrical interlocks, control transformer, and overload re-
lays. Each starter unit compartment is provided with an individual front door that is mechanically inter-
locked with the unit disconnect device to prevent opening the door while the unit is energized. Means
are provided for releasing this interlock for maintenance purposes.

GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354
DWG Number 106T5414 Rev B Released 3/26/2013 Page 1 of 13

SIZE DWG. NO. SH. REV.

B 106T5414 1 B
1. IF REQUIRED, THE CUSTOMER IS RESPONSIBLE FOR UPS (UNINTERUPTIBLE POWER SUPPLY) FOR NETWORK REVISIONS
EQUIPMENT. GE SUGGESTS THAT THE CUSTOMER USE SEPARATE CIRCUITS TO POWER THE REDUNDANT EQUIPMENT THIS DOCUMENT SHALL BE
(I.E. ETHERNET SWITCHES).
REV DESCRIPTION DATE IssuedBy
DEVICE APPROX. POWER @ 230 VAC / 50 HZ REVISED IN ITS ENTIRETY. ALL
HMI (WITH MONITOR) SHEETS OF THIS DOCUMENT A UPDATED TO SHOW DCS SCOPE ON
4 AMPS(EACH) 2013-03-01 RG21
ETHERNET SWITCHES < 1 AMP (EACH) ARE THE SAME REVISION LEVEL OVER VIEW SHEET PER ISS-0035992
NTP TIME SERVER (MAX. 61 WATTS) < 1 AMP (EACH) AS INDICATED IN THE REVISION
REMOTE SERVER GATEWAY < 3 AMP (EACH) BLOCK. UPDATED TO SHOW COMMUNICATION
PRINTER < 4 AMP (EACH) B BETWEEN TCP AND G023 FOR 2013-21-01 RG21
REMOVAL OF A315 PER ISS-0040239

2. THE SYMBOL DEFINES CUSTOMER'S SUPPLIED EQUIPMENT.

THE SYMBOL DEFINES THE TURBINE CONTROL PANEL (TCP).
THE SYMBOL DEFINES EQUIPMENT SUPPLIED FOR STEAM TURBINE ORDER
THE SYMBOL DEFINES EQUIPMENT SUPPLIED FOR DCS ORDER

3. LENGTHS OF CAT-6 UTP AND FIBER OPTIC CABLE ARE TO BE DETERMINED AT INSTALLATION.
4. EACH HUMAN MACHINE INTERFACE (HMI, EWS, APPLICATION GATEWAY, SYSTEM CONFIGURATION SERVER) AND MONITORING
PC (REMOTE SERVICES GATEWAY [RSG] AND GENX OSM) COMES WITH A 50 FT PRE-TERMINATED CAT-6 UTP (10 BASE-T)
CABLE PER NETWORK INTERFACE CARD PORT. THE OPERATOR INTERFACE (OI) USER INTERFACE DOES NOT INCLUDE
CONNECTING NETWORK CABLES. GE ALSO PROVIDES ONE ADDITIONAL 1000 FT SPOOL OF CAT-6 UTP (10 BASE-T) CABLE AND
THREE BOXES OF 20 RJ-45 CONNECTORS FOR THE SITE, WHICH SHOULD BE USED TO SATISFY THE AS-INSTALLED CABLE
LENGTH NEEDS. HOWEVER, IF ADDITIONAL CABLE OR CONNECTORS ARE REQUIRED, THE CUSTOMER IS RESPONSIBLE FOR
THE ADDITIONAL SUPPLY.

5. NETWORK HARDWARE THAT IS SUPPLIED BY GE IS SHIPPED LOOSE. THIS HARDWARE IS LOCATED AND INSTALLED BY THE
CUSTOMER.
ASSY, REMOTE CONTROL SYS
6. THE ON-SITE MONITOR (GENX OR GENX OSM), WHICH CONSISTS OF BOTH HARDWARE AND SOFTWARE, IS PROVIDED AT NO DESIGN MEMO: IPS720103
CHARGE TO THE CUSTOMER FOR THE LENGTH OF THE STANDARD WARRANTY PERIOD OR THE LENGTH OF ANY EXTENDED
CONTRACT SERVICE AGREEMENT (CSA). THE GENX IS USED TO PERIODICALLY MONITOR SELECTED UNIT AND FLEET DATA. IT GAS TURBINE: 299249
IS TYPICALLY MOUNTED IN THE REMOTE CONTROL ROOM. THE GENX WILL SUPPLIED WITH A DEDICATED CABINET, MONITOR,
KEYBOARD, CURSOR POSITIONING DEVICE. GE WILL ALSO PROVIDE A DEDICATED UPS, SIZED ONLY TO ACCOMMODATE THE GT GENERATOR: 324X039
GENX OSM. THE MONITORING SERVICE DOES NOT NECESSITATE OPERATOR INTERACTION FROM THE SITE. GE REQUIRES
THAT THE CUSTOMER PROVIDE A HIGH SPEED INTERNET CONNECTION IN ORDER TO ENSURE CONTINUED MONITORING. THE STEAM TURBINE: 270T888
HARDWARE AND SOFTWARE THAT IS INSTALLED FOR REMOTE MONITORING PURPOSES REMAINS THE PROPERTY OF GE AND
WILL BE REMOVED OR OTHERWISE DISABLED AT THE COMPLETION OF THE MONITORING PERIOD (UNLESS EXTENDED ST GENERATOR: 290T888
MONITORING HAS BEEN FURTHER NEGOTIATED).
MODEL LIST: 4108
7. ALL OPERATOR INTERFACES, INCLUDING THE HMI AND GENX OSM ARE TO BE LOADED WITH HARDWARE AND SOFTWARE
AUTHORIZED BY GE ENERGY ONLY THE INSTALLATION OF ANY SOFTWARE OR HARDWARE NOT AUTHORIZED BY GE ENERGY CUSTOMER: Siddhirganj 335 MW Combined Cycle Power
WILL VOID GE WARRANTY AGREEMENTS AND MAY CAUSE NETWORK INTERFACE PROBLEMS.

8. THE CUSTOMER AGREES BY USE OF THE GE CONTROL SYSTEM THAT THE TOOLS, SOFTWARE, COPYRIGHTED OPERATOR
STATION SCREENS, DRAWINGS, SCHEMATICS, LOGIC, AND OTHER INTELLECTUAL PROPERTY PROVIDED WITH GE’S CONTROL
SYSTEMS, OPERATOR STATIONS, AND RELATED COMPONENTS ARE PROPRIETARY INFORMATION OWNED BY GE OR OTHER NOTE: SHEETS 5 THROUGH
PARTIES, PROTECTED BY LAW, AND LICENSED TO THE CUSTOMER FOR THEIR USE ON THEIR SPECIFIC PROJECT
APPLICATION ONLY. THE CUSTOMER IS EXPRESSLY FORBIDDEN FROM REVERSE ENGINEERING, DECOMPILING, OR 13 WERE DELETED FROM
OTHERWISE DERIVING THE SOURCE OF THE PROPRIETARY INFORMATION THROUGH ANY MEANS OR FROM REPRODUCING,
DISTRIBUTING, DISCLOSING, OR ALLOWING ACCESS TO ANY GE PROPRIETARY INFORMATION, IN ANY FORM, TO ANY THIRD THIS COPY FOR OPERATIONS
PARTY, WITHOUT GE'S PRIOR WRITTEN PERMISSION. SUCH AUTHORIZATION WILL LIKELY REQUIRE AN AGREEMENT
BETWEEN GE AND THE THIRD PARTY.
TRAINING PURPOSES 2014
9. THE REMOTE SERVICE GATEWAY (RSG), WHICH CONSISTS OF BOTH HARDWARE AND SOFTWARE, IS PROVIDED AT NO
CHARGE TO THE CUSTOMER FOR THE LENGTH OF THE STANDARD WARRANTY PERIOD AND CAN BE USED THROUGHOUT THE
TERM OF AN EXTENDED CONTRACT SERVICE AGREEMENT (CSA) WITH A SEPARATE AGREEMENT IN PLACE. THE RSG IS USED
FOR THE REMOTE DIAGNOSTICS AND TROUBLESHOOTING OF GE CONTROL SYSTEMS. THE RSG COLLECTS HISTORICAL GE CLASS II ( INTERNAL NON-CRITICAL )
ALARM AND SIGNAL DATA AND CONTAINS COPIES OF THE CUSTOMER’S CONTROL SYSTEM SOFTWARE TO ALLOW FOR LIVE
SIGNATURES DATE
g
UNLESS OTHERWISE SPECIFIED
DATA COLLECTION AND VIEWING OF LOGIC IN THE CONTROL SYSTEM. GE REQUIRES THAT THE CUSTOMER PROVIDE A HIGH- GENERAL ELECTRIC COMPANY
SPEED INTERNET CONNECTION TO THE RSG TO ALLOW FOR RELIABLE REMOTE ACCESS. THE HARDWARE AND SOFTWARE DIMENSIONS ARE IN INCHES
DRAWN
GUDA RAGHU 2012-12-17 GE Energy Products
THAT IS INSTALLED FOR REMOTE MONITORING PURPOSES REMAINS THE PROPERTY OF GE AND WILL BE REMOVED OR TOLERANCES ON CHECKED
2 PL DECIMALS ± SEE PLM
OTHERWISE DISABLED AT THE COMPLETION OF THE MONITORING PERIOD (UNLESS EXTENDED MONITORING HAS BEEN 3 PL DECIMALS ± ENGRG
FURTHER NEGOTIATED). ANGLES ± GUDA RAGHU 2012-12-17
C COPYRIGHT 2013 GENERAL ELECTRIC COMPANY FRACTIONS ± ISSUED
SEE PLM ASSY, REMOTE CONTROL SYS
THIRD ANGLE PROJECTION PROPRIETARY INFORMATION-THIS DOCUMENT CONTAINS FIRST MADE FOR: ML-9K1WFA163-1 4108
PROPRIETARY INFORMATION OF GENERAL ELECTRIC
APPLIED SIZE CAGE CODE DWG NO
PRACTICES
COMPANY AND MAY NOT BE USED OR DISCLOSED TO
OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF
B 106T5414
SCALE SHEET
GENERAL ELECTRIC COMPANY. 1 of 13

0
SIM TO:
0

DT-1N IPS720103, 4108 CE1D

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T5414 Rev B Released 3/26/2013 Page 2 of 13

SIZE
B
DWG. NO.
106T5414 SH.
2
REV.
B

ETHERNET EQUIPMENT ETHERNET EQUIPMENT ETHERNET EQUIPMENT

ID ID ID
# DESCRIPTION IDENT. SUPPLIER DESCRIPTION IDENT. SUPPLIER DESCRIPTION IDENT. SUPPLIER
# #
DUAL FIBER PORT;
FIBER OPTIC CABLE MULTI-MODE VLAN CISCO 2960S ETHERNET SWITCH
1 (MULTI-MODE)
216A5771 NA 23 PARTIAL VLAN ETHERNET SWITCH(SEE - NA 44 - NA
NOTE 5) (SEE NOTE 5)

FIBER OPTIC CONNECTOR - SINGLE-MODE CISCO 2960S 4SFP ETHERNET SWITCH

2 (TYPE SC)
377A2080 NA 24 TRANSCEIVER BY GE 45
(IN CUSTOMER CONTROL ROOM LOCATION)
- NA

FIBER OPTIC CONN. ASM KIT ROUTER MULTI-MODE CISCO 2960S 4SFP ETHERNET SWITCH
3 377A2081 NA 25 - BY GE 46 - NA
(TYPE SC, ONE PER SITE) (SEE NOTE 5) (IN CUSTOMER CONTROL ROOM LOCATION)

FIBER OPTIC CONNECTOR SINGLE-MODE CISCO 2960S 2SFP ETHERNET SWITCH

4 CAT-6 UTP ETHERNET CABLE( SEE NOTE 4) - BY GE 26 352A6500 NA 47 - NA
(TYPE ST) (IN CUSTOMER CONTROL ROOM LOCATION)

CAT-6 UTP ETHERNET CABLE FIBER OPTIC CONN. ASM KIT MULTI-MODE CISCO 2960S 2SFP ETHERNET SWITCH
5 - BY GE 27 352A6501 NA 48 (IN CUSTOMER CONTROL ROOM LOCATION) - NA
CONNECTOR(RJ-45)(SEE NOTE 4) (TYPE ST, ONE PER SITE)

10 BASE-2 ETHERNET CABLE NTP TIME SERVER

6 - NA 28 (IRIG-B INPUT BY OTHERS) - NA 49 SINGLE-MODE FIBER OPTIC CABLE - BY CUSTOMER
(RG-58 COAXIAL)

10 BASE-2 CONNECTOR NTP TIME SERVER SINGLE-MODE FIBER OPTIC CONNECTOR

7 - NA 29 - NA 50 - BY CUSTOMER
(RG-58 COAXIAL) (GPS INPUT BY GE) (TYPE LC)

NTP TIME SERVER

8 RS-232 MODBUS CABLE - NA 30
(GPS INPUT BY GE W/ IRIG OUTPUTS)
- BY GE 51 MULTI-MODE FIBER OPTIC CABLE - NA

RS-232 MODBUS CABLE MULTI-MODE FIBER OPTIC CONNECTOR

9 (FROM HMI TO FIRST LDDS)
- NA 31 TIME SYNCH DISTRIBUTION PANEL - NA 52 - NA
(TYPE LC)

RS-232 MODBUS MODEM

10 (LDDS)
- NA 32 NETWORK PRINT SERVER - NA 53 SINGLE-MODE FIBER 10M CABLE WITH LC CONNECTOR - NA

CROSSOVER UTP CABLE MULTI-MODE FIBER 10M CABLE WITH LC

11 - NA 33 HMI / PEECC RACK - TALL - NA 54 - NA
(3FT PRETERMINATED LENGTHS) CONNECTOR

SINGLE-MODE VLAN CISCO 3750X 6SFP ETHERNET

12 MONITOR SWITCH - NA 34 HMI / PEECC RACK - SHORT - NA 55 SWITCH - NA
(IN CUSTOMER CONTROL ROOM)
HIGH SPEED INTERNET CONNECTION MULTI-MODE VLAN CISCO 3750X 6SFP ETHERNET
13 - BY CUSTOMER 35 EQUIPMENT NETWORK RACK - NA 56 SWITCH - NA
(HSC) (ETHERNET)
(IN CUSTOMER CONTROL ROOM)
DUAL FIBER PORT; SINGLE-MODE VLAN CISCO 3750X 12SFP ETHERNET
14 NA - NA 36 VLAN ETHERNET SWITCH w/ PORT - NA 57 SWITCH - BY GE
TRIGGERING(SEE NOTE 5) (IN CUSTOMER CONTROL ROOM)
DUAL FIBER PORT; MULTI-MODE VLAN CISCO 3750X 12SFP ETHERNET
15 MEDIA CONVERTER(SEE NOTES 5) - NA 37 VLAN ETHERNET SWITCH ROOT - NA 58 SWITCH - NA
BRIDGE(SEE NOTE 5) (IN CUSTOMER CONTROL ROOM)
NETWORK INTERFACE CARD NETWORK BLADE SWITCH SINGLE-MODE VLAN CISCO 3750X 24SFP ETHERNET
16 - BY GE 38 - NA 59 SWITCH - NA
(NIC) N3 CHASSIS
(IN CUSTOMER CONTROL ROOM)

SINGLE FIBER PORT; MULTI-MODE VLAN CISCO 3750X 24SFP ETHERNET

17 - NA NETWORK BLADE SWITCH
ETHERNET SWITCH(SEE NOTE 5) 39 N5 CHASSIS - NA 60 SWITCH - NA
(IN CUSTOMER CONTROL ROOM)
DUAL FIBER PORT; SINGLE-MODE CISCO 2960S 4SFP ETHERNET SWITCH
18 - NA 40 LOCK BOX - BY GE 61 - NA
ETHERNET SWITCH(SEE NOTE 5) (IN CUSTOMER CONTROL ROOM LOCATION)

MULTIPLE FIBER PORT; STACKING CABLE MULTI-MODE CISCO 2960S 4SFP ETHERNET SWITCH
19 - NA 41 - BY GE 62 - NA
ETHERNET SWITCH(SEE NOTE 5) (CATALYST 2960S) (IN CUSTOMER CONTROL ROOM LOCATION)

20 NA - NA STACKING CABLE
42 - BY GE 63 UNIVERSAL NETWORK EQUIPMENT DIMENSIONS - BY GE
(CATALYST 3750X)
DUAL FIBER PORT;
21 - NA SINGLE-MODE VLAN CISCO 2960S
VLAN ETHERNET SWITCH(SEE NOTE 5) 43 - BY GE
ETHERNET SWITCH
MULTIPLE FIBER PORT;
22 VLAN ETHERNET SWITCH ROOT - NA
BRIDGE(SEE NOTE 5)
SIZE CAGE CODE DWG NO
4108
g GENERAL ELECTRIC COMPANY B
106T5414
NOTE: THE EQUIPMENT LISTED APPLIES TO UDH SHEETS, PDH SHEETS AND TRUNK

DISTR
DRAWN GUDA RAGHU 2012-12-17
CONNECTIONS SHEETS ONLY

TO
ISSUED SCALE SHEET
SEE PLM 2 of 13

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T5414 Rev B Released 3/26/2013 Page 3 of 13

SIZE
B
DWG. NO.
106T5414 SH.
3
REV.
B

G1 PEECC G1 EC G1 LC S1 ELECTRICAL ROOM

G1 E1 L1 S1 X1 ELEC BOP MECH BOP HRSG1

Mark VIe EX2100e LS2100e Mark VIe EX2100e Mark VIe Mark VIe Mark VIe

R S T M1 M2 C A B R S T M1 M2 R S R S R S

CENTRAL CONTROL ROOM

UDH A
UDH B

REMOTE SERVICE
GATEWAY

Genx OSM
On Site Monitor GT1_SVR

M
Site Router /
Firewall ADH ADH

LockBox
ISP Circuit / HSC

ENGINEERING ROOM Color Laser Printer

PDH A
PDH B

SIZE CAGE CODE DWG NO

4108
g GENERAL ELECTRIC COMPANY B
SINGLE LINE OVERVIEW – SH1 106T5414

DISTR
DRAWN GUDA RAGHU 2012-12-17

TO
NOTE: THE “M” DENOTES MULTI-UNIT CAPABILITY OF THE HMI. ISSUED SCALE SHEET
SEE PLM 3 of 13

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 106T5414 Rev B Released 3/26/2013 Page 4 of 13

SIZE
B
DWG. NO.
106T5414 SH.
4
REV.
B

BY OTHERS

REMOTE
DISPATCH

Firewall
GPS
Router

UDH A
UDH B

AUX. CONSOLE
Trip Buttons
&
Indicators

70" Large
Screen NTP_1

PERFORMANCE OPC GATEWAY1 OPC GATEWAY2

CEMS-DAHS
HMI1 HMI2 MANAGEMENT HISTORIAN EWS
CRM1_SVR STCRM1_SVR (OPTION)
STATION
2 x IRIG-B OUTPUT

M M M M 20" 22" 22" 22" 22"

M
22" 22" 22"

ENGINEERING ROOM

PDH A
PDH B

Color Laser Printer/PRN 1 Color Laser Printer/PRN 2 Color Laser Printer/PRN 2 Color Laser Printer/PRN 3 Color Laser Printer/PRN 4 Color Laser Printer/PRN 5 B&W Laser Printer/PRN 6 B&W Laser Printer/PRN 7

CENTRAL CONTROL ROOM

CEMS

BY OTHERS

SIZE CAGE CODE DWG NO

4108
g GENERAL ELECTRIC COMPANY B
SINGLE LINE OVERVIEW – SH2 106T5414

DISTR
DRAWN GUDA RAGHU 2012-12-17

TO
NOTE: THE “M” DENOTES MULTI-UNIT CAPABILITY OF THE HMI. ISSUED SCALE SHEET
SEE PLM 4 of 13

GE Proprietary Information - Class II (Internal) US EAR - NLR

 GE Power Systems

FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM

SPEEDTRONIC Mark VI Control contains a celeration, speed, temperature, shutdown, and

number of control, protection and sequencing sys- manual control functions illustrated in Figure 1.
tems designed for reliable and safe operation of the Sensors monitor turbine speed, exhaust tempera-
gas turbine. It is the objective of this chapter to de- ture, compressor discharge pressure, and other pa-
scribe how the gas turbine control requirements are rameters to determine the operating conditions of
met, using simplified block diagrams and one–line the unit. When it is necessary to alter the turbine op-
diagrams of the SPEEDTRONIC Mark VI control, erating conditions because of changes in load or am-
protection, and sequencing systems. A generator bient conditions, the control modulates the flow of
drive gas turbine is used as the reference. fuel to the gas turbine. For example, if the exhaust
temperature tends to exceed its allowable value for a
CONTROL SYSTEM given operating condition, the temperature control
system reduces the fuel supplied to the turbine and
Basic Design thereby limits the exhaust tempera-
Control of the gas turbine is done by the startup, ac- ture.

TO CRT DISPLAY

FUEL
TEMPERATURE

TO CRT DISPLAY
FSR
FUEL
SPEED MINIMUM SYSTEM
VALUE
SELECT
LOGIC

ACCELERATION
RATE TO TURBINE
TO CRT
DISPLAY

START
UP
SHUT
DOWN
MANUAL
id0043

Figure 1 Simplified Control Schematic

Operating conditions of the turbine are sensed and modes of acceleration, manual FSR, and shutdown
utilized as feedback signals to the SPEEDTRONIC operate in a similar manner.
control system. There are three major control loops –
startup, speed, and temperature – which may be in Fuel Stroke Reference (FSR) is the command signal
control during turbine operation. The output of these for fuel flow. The minimum value select gate con-
control loops is connected to a minimum value gate nects the output signals of the six control modes to
circuit as shown in Figure 1. The secondary control the FSR controller; the lowest FSR output of the six
Fund_Mk_VI 1 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

LOGIC FSRSU <R><S><T>

START-UP
CQTC CONTROL

<R><S><T>
FSR FSRACC ACCELERATION
TNHAR CONTROL
LOGIC TNH
TNH TNHAR
FSRMIN

FSRSU FSR
<R><S><T>
LOGIC FSRMAN MANUAL FSR FSRACC
FSRC FSRMAN
FSRSD FSR
MIN
FSRN GATE
FSRT

LOGIC FSRSD
<R><S><T>
FSRC SHUTDOWN
TNHCOR FSRMIN CONTROL
FSR
CQTC
FSRMIN

SPEED CONTROL <R><S><T>

LOGIC
TTUR
VTUR
TNH
77NH PR/D FSRN

LOGIC TNR
TNR

LOGIC TNRI ISOCHRONOUS

TNRI ONLY

TEMPERATURE CONTROL
LOGIC TTRX
TBAI
VAIC <R><S><T>
96CD A/D
TTRX FSRT
FSR
LOGIC
<R><S><T>
FSR
TBTC TTXM
VTCC
TTXD <R><S><T> TTXM
TTXD A/D
MEDIAN

id0038V

Figure 2 Block Diagram – Control Schematic

FUNDAMENTALS OF SPEEDTRONIC 2 Fund_Mk_VI

MARK VI CONTROL SYSTEM
 GE Power Systems

control loops is allowed to pass through the gate to The following speed detectors and speed relays are
the fuel control system as the controlling FSR. The typically used:
controlling FSR will establish the fuel input to the
–L14HR Zero–Speed (approx. 0% speed)
turbine at the rate required by the system which is in
control. Only one control loop will be in control at –L14HM Minimum Speed (approx. 16%
any particular time and the control loop which is speed)
controlling FSR will be displayed on the <HMI>.
–L14HA Accelerating Speed (approx. 50%
Figure 2 shows a more detailed schematic of the speed)
control loops. This can be referenced during the ex- –L14HS Operating Speed (approx. 95%
planation of each loop to show the interfacing. speed)
The zero–speed detector, L14HR, provides the sig-
Start–up/Shutdown Sequence and Control nal when the turbine shaft starts or stops rotating.
When the shaft speed is below 14HR, or at zero–
Start–up control brings the gas turbine from zero speed, L14HR picks–up (fail safe) and the permis-
speed up to operating speed safely by providing sive logic initiates turning gear or slow–roll
proper fuel to establish flame, accelerate the turbine, operation during the automatic start–up sequence of
and to do it in such a manner as to minimize the low the turbine.
cycle fatigue of the hot gas path parts during the se- The minimum speed detector L14HM indicates that
quence. This involves proper sequencing of com- the turbine has reached the minimum firing speed
mand signals to the accessories, starting device and and initiates the purge cycle prior to the introduction
fuel control system. Since a safe and successful of fuel and ignition. The dropout of the L14HM
start–up depends on proper functioning of the gas minimum speed relay provides several permissive
turbine equipment, it is important to verify the state functions in the restarting of the gas turbine after
of selected devices in the sequence. Much of the shutdown.
control logic circuitry is associated not only with ac-
The accelerating speed relay L14HA pickup indi-
tuating control devices, but enabling protective cir-
cates when the turbine has reached approximately
cuits and obtaining permissive conditions before
50 percent speed; this indicates that turbine start–up
proceeding.
is progressing and keys certain protective features.
The gas turbine uses a static start system whereby The high–speed sensor L14HS pickup indicates
the generator serves as a starting motor. A turning when the turbine is at speed and that the accelerating
gear is used for rotor breakaway. sequence is almost complete. This signal provides
General values for control settings are given in this the logic for various control sequences such as stop-
description to help in the understanding of the oper- ping auxiliary lube oil pumps and starting turbine
ating system. Actual values for control settings are shell/exhaust frame blowers.
given in the Control Specifications for a particular Should the turbine and generator slow during an un-
machine. derfrequency situation, L14HS will drop out at the
under–frequency speed setting. After L14HS drops
Speed Detectors out the generator breaker will trip open and the Tur-
bine Speed Reference (TNR) will be reset to
An important part of the start–up/shutdown se- 100.3%. As the turbine accelerates, L14HS will
quence control of the gas turbine is proper speed again pick up; the turbine will then require another
sensing. Turbine speed is measured by magnetic start signal before the generator will attempt to auto–
pickups and will be discussed under speed control. synchronize to the system again.
Fund_Mk_VI 3 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

The actual settings of the speed relays are listed in OR LOWER” allows manual adjustment of FSR
the Control Specification and are programmed in the setting between FSRMIN and FSRMAX.
<RST> processors as EEPROM control constants.
While the turbine is at rest, electronic checks are
made of the fuel system stop and control valves, the
accessories, and the voltage supplies. At this time,
START–UP CONTROL “SHUTDOWN STATUS” will be displayed on the
<HMI>. Activating the Master Operation Switch
The start–up control operates as an open loop con- (L43) from “OFF” to an operating mode will acti-
trol using preset levels of the fuel command signal vate the ready circuit. If all protective circuits and
FSR. The levels are: “ZERO”, “FIRE”, “WARM– trip latches are reset, the “STARTUP STATUS” and
UP”, “ACCELERATE” and “MAX”. The Control “READY TO START” messages will be displayed,
Specifications provide proper settings calculated for indicating that the turbine will accept a start signal.
the fuel anticipated at the site. The FSR levels are set Clicking on the “START” Master Control Switch
as Control Constants in the SPEEDTRONIC Mark (L1S) and “EXECUTE” will introduce the start sig-
VI start–up control. nal to the logic sequence.

Start–up control FSR signals operate through the The start signal energizes the Master Control and
minimum value gate to ensure that other control Protection circuit (the “L4” circuit) and starts the
functions can limit FSR as required. necessary auxiliary equipment. The “L4” circuit
permits pressurization of the trip oil system. With
The fuel command signals are generated by the the “L4” circuit permissive and starting clutch auto-
SPEEDTRONIC control start–up software. In addi- matically engaged, the starting device starts turning.
tion to the three active start–up levels, the software Startup status message “STARTING” will be dis-
sets maximum and minimum FSR and provides for played on the <HMI>. See point “A” on the Typical
manual control of FSR. Clicking on the targets for Start–up Curve Figure
“MAN FSR CONTROL” and “FSR GAG RAISE 3.
SPEED – %
100

80
ACCELERATE
IGNITION &
CROSSFIRE WARMUP
60 IGV – DEGREES
START 1 MIN
AUXILIARIES &
DIESEL WARMUP
Tx – °F/10

40 PURGE COAST

DOWN

20
FSR – %

0
A B D
APPROXIMATE TIME – MINUTES id0093

Figure 3 Mark VI Start-up Curve

FUNDAMENTALS OF SPEEDTRONIC 4 Fund_Mk_VI

MARK VI CONTROL SYSTEM
 GE Power Systems

The starting clutch is a positive tooth type overrun- eration. This is done by programming a slow rise in
ning clutch which is self–engagifng in the break- FSR. See point “C” on Figure 3. As fuel is increased,
away mode and overruns whenever the turbine rotor the turbine begins the acceleration phase of start–up.
exceeds the turning gear speed. The clutch is held in as long as the turning gear pro-
vides torque to the gas turbine. When the turbine
When the turbine ‘breaks away’ the turning gear will overruns the turning gear, the clutch will disengage,
rotate the turbine rotor from 5 to 7 rpm. As the static shutting down the turning gear. Speed relay L14HA
starter begins it’s sequence, and accelerates the rotor indicates the turbine is accelerating.
the starting clutch will automatically disengage the
turning gear from the turbine rotor. The turbine The start–up phase ends when the unit attains full–
speed relay L14HM indicates that the turbine is turn- speed–no–load (see point “D” on Figure 3). FSR is
ing at the speed required for proper purging and igni- then controlled by the speed loop and the auxiliary
tion in the combustors. Gas fired units that have systems are automatically shut down.
exhaust configurations which can trap gas leakage
The start–up control software establishes the maxi-
(i.e., boilers) have a purge timer, L2TV, which is ini-
mum allowable levels of FSR signals during start–
tiated with the L14HM signal. The purge time is set
up. As stated before, other control circuits are able to
to allow three to four changes of air through the unit
reduce and modulate FSR to perform their control
to ensure that any combustible mixture has been
functions. In the acceleration phase of the start–up,
purged from the system. The starting means will
FSR control usually passes to acceleration control,
hold speed until L2TV has completed its cycle.
which monitors the rate of rotor acceleration. It is
Units which do not have extensive exhaust systems
possible, but not normal, to reach the temperature
may not have a purge timer, but rely on the starting
control limit. The <HMI> display will show which
cycle and natural draft to purge the system.
parameter is limiting or controlling FSR.
The L14HM signal or completion of the purge cycle
(L2TVX) ‘enables’ fuel flow, ignition, sets firing Fired Shutdown
level FSR, and initiates the firing timer L2F. See
point “B” on Figure 3. When the flame detector out- A normal shutdown is initiated by clicking on the
put signals indicate flame has been established in the “STOP” target (L1STOP) and “EXECUTE”; this
combustors (L28FD), the warm–up timer L2W will produce the L94X signal. If the generator break-
starts and the fuel command signal is reduced to the er is closed when the stop signal is initiated, the Tur-
“WARM–UP” FSR level. The warm–up time is pro- bine Speed Reference (TNR) counts down to reduce
vided to minimize the thermal stresses of the hot gas load at the normal loading rate until the reverse pow-
path parts during the initial part of the start–up. er relay operates to open the generator breaker; TNR
then continues to count down to reduce speed. When
If flame is not established by the time the L2F timer the STOP signal is given, shutdown Fuel Stroke Ref-
times out, typically 60 seconds, fuel flow is halted. erence FSRSD is set equal to FSR.
The unit can be given another start signal, but firing
will be delayed by the L2TV timer to avoid fuel ac- When the generator breaker opens, FSRSD ramps
cumulation in successive attempts. This sequence from existing FSR down to a value equal to
occurs even on units not requiring initial L2TV FSRMIN, the minimum fuel required to keep the
purge. turbine fired. FSRSD latches onto FSRMIN and de-
creases with corrected speed. When turbine speed
At the completion of the warm–up period (L2WX), drops below a defined threshold (Control Constant
the start–up control ramps FSR at a predetermined K60RB) FSRSD ramps to a blowout of one flame
rate to the setting for “ACCELERATE LIMIT”. The detector. The sequencing logic remembers which
start–up cycle has been designed to moderate the flame detectors were functional when the breaker
highest firing temperature produced during accel- opened. When any of the functional flame detectors
Fund_Mk_VI 5 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

senses a loss of flame, FSRMIN/FSRSD decreases Speed/Load Reference

at a higher rate until flame–out occurs, after which
fuel flow is stopped. The speed control software will change FSR in pro-
Fired shut down is an improvement over the former portion to the difference between the actual turbine–
fuel shut off at L14HS drop out. By maintaining generator speed (TNH) and the called–for speed
flame down to a lower speed there is significant re- reference (TNR).
duction in the strain developed on the hot gas path The called–for–speed, TNR, determines the load of
parts at the time of fuel shut off. the turbine. The range for generator drive turbines is
normally from 95% (min.) to 107% (max.) speed.
The start–up speed reference is 100.3% and is preset
SPEED CONTROL when a “START” signal is given.

The Speed Control System controls the speed and TNR MAX. HIGH SPEED STOP
107
load of the gas turbine generator in response to the
actual turbine speed signal and the called–for speed
reference. While on speed control the control mode 104
message “SPEED CTRL”will be displayed.

Speed Signal
REFERENCE % (TNR)
SPEED

“FSNL”
Three magnetic sensors are used to measure the 100

speed of the turbine. These magnetic pickup sensors

FULL SPEED NO LOAD FSR

RATED FSR
(77NH–1,–2,–3) are high output devices consisting
of a permanent magnet surrounded by a hermetically
MINIMUM FSR

sealed case. The pickups are mounted in a ring

MAX FSR
around a 60–toothed wheel on the gas turbine com-
pressor rotor. With the 60–tooth wheel, the frequen-
LOW SPEED STOP
cy of the voltage output in Hertz is exactly equal to 95
TNR MIN.
the speed of the turbine in revolutions per minute. FUEL STROKE REFERENCE (LOAD)
(FSR)
id0044
The voltage output is affected by the clearance be- Figure 4 Droop Control Curve
tween the teeth of the wheel and the tip of the mag-
netic pickup. Clearance between the outside
diameter of the toothed wheel and the tip of the mag- The turbine follows to 100.3% TNH for synchro-
netic pickup should be kept within the limits speci- nization. At this point the operator can raise or lower
fied in the Control Specifications (approx. 0.05 inch TNR, in turn raising or lowering TNH, via the
or 1.27 mm). If the clearance is not maintained with- 70R4CS switch on the generator control panel or by
in the specified limits, the pulse signal can be dis- clicking on the targets on the <HMI>, if required.
torted. Turbine speed control would then operate in Refer to Figure 4. Once the generator breaker is
response to the incorrect speed feedback signal. closed onto the power grid, the speed is held
constant by the grid frequency. Fuel flow in excess
The signal from the magnetic pickups is brought into of that necessary to maintain full speed no load will
the Mark VI panel, one mag pickup to each control- result in increased power produced by the generator.
ler <RST>, where it is monitored by the speed con- Thus the speed control loop becomes a load control
trol software. loop and the speed reference is a convenient control
FUNDAMENTALS OF SPEEDTRONIC 6 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

of the desired amount of load to be applied to the tur- units have the same droop, all will share a load in-
bine–generator unit. crease equally. Load sharing and system stability are
the main advantages of this method of speed control.
Droop speed control is a proportional control,
changing FSR in proportion to the difference be- Normally 4% droop is selected and the setpoint is
tween actual turbine speed and the speed reference. calibrated such that 104% setpoint will generate a
Any change in actual speed (grid frequency) will speed reference which will produce an FSR result-
cause a proportional change in unit load. This pro- ing in base load at design ambient temperature.
portionality is adjustable to the desired regulation or
When operating on droop control, the full–speed–
“Droop”. The speed vs. FSR relationship is shown
no–load FSR setting calls for a fuel flow which is
on Figure 4.
sufficient to maintain full speed with no generator
If the entire grid system tends to be overloaded, grid load. By closing the generator breaker and raising
frequency (or speed) will decrease and cause an FSR TNR via raise/lower, the error between speed and
increase in proportion to the droop setting. If all reference is increased. This error is multiplied by a
<RST>

SPEED CONTROL

FSNL

TNR
SPEED
REFERENCE

+ ERROR + FSRN
+
– SIGNAL

TNH
SPEED
DROOP

<RST>
SPEED CHANGER LOAD SET POINT

MAX. LIMIT
L83SD
RATE
MEDIAN
L70R SELECT
RAISE
L70L
LOWER
L83PRES TNR
PRESET SPEED
LOGIC REFERENCE

PRESET

OPERATING

L83TNROP MIN.
MIN. SELECT LOGIC

START-UP
OR SHUTDOWN
id0040

Figure 5 Speed Control Schematic

Fund_Mk_VI 7 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
 GE Power Systems

gain constant dependent on the desired droop setting start–up control can drive FSR to zero and are not in-
and added to the FSNL FSR setting to produce the fluenced by FSRMIN.
required FSR to take more load and thus assist in
holding the system frequency. Refer to Figures 4 and
5. Synchronizing

The minimum FSR limit (FSRMIN) in the SPEED- Automatic synchronizing is accomplished using
TRONIC Mark VI system prevents the speed con- synchronizing algorithms programmed into <RST>
trol circuits from driving the FSR below the value and <VPRO> software. Bus and generator voltage
which would cause flameout during a transient signals are input to the <VPRO> core which con-
condition. For example, with a sudden rejection of tains isolation transformers, and are then paralleled
load on the turbine, the speed control system loop to <RST>. <RST> software drives the synch check
would want to drive the FSR signal to zero, but the and synch permissive relays, while <VPRO> pro-
minimum FSR setting establishes the minimum fuel vides the actual breaker close command. See Figure
level that prevents a flameout. Temperature and/or 6.

<XYZ>
AUTO SYNCH

<RST>
AUTO SYNCH
PERMISSIVE
CALCULATED PHASE WITHIN LIMITS AND

GEN VOLTS A CALCULATED SLIP WITHIN LIMITS

A>B L25
REF B AND L83AS BREAKER
AUTO SYNCH CLOSE
CALCULATED ACCELERATION
PERMISSIVE
LINE VOLTS
A
A>B CALCULATED BREAKER LEAD TIME
REF B

id0048V

Figure 6 Synchronizing Control Schematic

There are three basic synchronizing modes. These For synchronizing, the unit is brought to 100.3%
may be selected from external contacts, i.e., genera- speed to keep the generator “faster” than the grid, as-
tor panel selector switch, or from the SPEEDTRON- suring load pick–up upon breaker closure. If the sys-
IC Mark VI <HMI>. tem frequency has varied enough to cause an
unacceptable slip frequency (difference between
1. OFF – Breaker will not be closed by SPEED- generator frequency and grid frequency), the speed
TRONIC Mark VI control matching circuit adjusts TNR to maintain turbine
speed 0.20% to 0.40% faster than the grid to assure
2. MANUAL – Operator initiated breaker closure
the correct slip frequency and permit synchronizing.
when permissive synch check relay 25X is satis-
fied
For added protection a synchronizing check relay is
3. AUTO – System will automatically match volt- provided in the generator panel. It is used in series
age and speed and then close the breaker at the with both the auto synchronizing relay and the
appropriate time to hit top dead center on the manual breaker close switch to prevent large out–
synchroscope of–phase breaker closures.
FUNDAMENTALS OF SPEEDTRONIC 8 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

ACCELERATION CONTROL turbine occurs in the flame zone of the combustion

chambers. The combustion gas in that zone is di-
Acceleration control compares the present value of luted by cooling air and flows into the turbine sec-
the speed signal with the value at the last sample tion through the first stage nozzle. The temperature
time. The difference between these two numbers is a of that gas as it exits the first stage nozzle is known as
measure of the acceleration. If the actual accelera- the “firing temperature” of the gas turbine; it is this
tion is greater than the acceleration reference, temperature that must be limited by the control sys-
FSRACC is reduced, which will reduce FSR, and tem. From thermodynamic relationships, gas tur-
consequently the fuel to the gas turbine. During bine cycle performance calculations, and known site
start–up the acceleration reference is a function of conditions, firing temperature can be determined as
turbine speed; acceleration control usually takes a function of exhaust temperature and the pressure
over from speed control shortly after the warm–up ratio across the turbine; the latter is determined from
period and brings the unit to speed. At “Complete the measured compressor discharge pressure (CPD).
Sequence”, which is normally 14HS pick–up, the The temperature control system is designed to mea-
acceleration reference is a Control Constant, nor- sure and control turbine exhaust temperature rather
mally 1% speed/second. After the unit has reached than firing temperature because it is impractical to
100% TNH, acceleration control usually serves only measure temperatures directly in the combustion
to contain the unit’s speed if the generator breaker chambers or at the turbine inlet. This indirect control
should open while under load. of turbine firing temperature is made practical by
utilizing known gas turbine aero– and thermo–dy-
namic characteristics and using those to bias the ex-
haust temperature signal, since the exhaust
temperature alone is not a true indication of firing
ISOTHERMAL
temperature.
EXHASUT TEMPERATURE (Tx)

Firing temperature can also be approximated as a

function of exhaust temperature and fuel flow (FSR)
and as a function of exhaust temperature and genera-
tor output (DWATT). Either FSR or megawatt ex-
haust temperature control curves are used as
back–up to the primary CPD–biased temperature
control curve.
These relationships are shown on Figures 7 and 8.
The lines of constant firing temperature are used in
the control system to limit gas turbine operating
COMPRESSOR DISCHARGE PRESSURE (CPD)
id0045 temperatures, while the constant exhaust tempera-
Figure 7 Exhaust Temperature vs.
ture limit protects the exhaust system during start–
Compressor Discharge Pressure up.

Exhaust Temperature Control Hardware

TEMPERATURE CONTROL
Chromel–Alumel exhaust temperature thermocou-
The Temperature Control System will limit fuel ples are used and, typically 27 in number. These
flow to the gas turbine to maintain internal operating thermocouples circumferentially inside the exhaust
temperatures within design limitations of turbine diffuser. They have individual radiation shields that
hot gas path parts. The highest temperature in the gas allow the radial outward diffuser flow to pass over
Fund_Mk_VI 9 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

tive exhaust temperature value, compares this value

with the setpoint, and then generates a fuel com-
mand signal to the analog control system to limit ex-
haust temperature.
ISOTHERMAL

Temperature Control Command Program

EXHASUT TEMPERATURE (Tx)

The temperature control command program

compares the exhaust temperature control setpoint
with the measured gas turbine exhaust temperature
as obtained from the thermocouples mounted in the
exhaust plenum; these thermocouples are scanned
and cold junction corrected by programs described
later. These signals are accessed by <RST>. The
temperature control command program in <RST>
FUEL STROKE REFERENCE (FSR) (Figure 9) reads the exhaust thermocouple tempera-
id0046
ture values and sorts them from the highest to the
Figure 8 Exhaust Temperature vs. Fuel lowest. This array (TTXD2) is used in the combus-
Control Command Signal
tion monitor program as well as in the Temperature
these 1/16” diameter (1.6mm) stainless steel Control Program. In the Temperature Control Pro-
sheathed thermocouples at high velocity, minimiz- gram all exhaust thermocouple inputs are monitored
ing the cooling effect of the longer time constant, and if any are reading too low as compared to a
cooler plenum walls. The signals from these individ- constant, they will be rejected. The highest and low-
ual, ungrounded detectors are sent to the SPEED- est values are then rejected and the remaining values
TRONIC Mark VI control panel through shielded are averaged, that average being the TTXM signal.
thermocouple cables and are divided amongst con- If a Controller should fail, this program will ignore
trollers <RST>. the readings from the failed Controller. The TTXM
signal will be based on the remaining Controllers’
Exhaust Temperature Control Software thermocouples and an alarm will be generated.
The TTXM value is used as the feedback for the ex-
The software contains a series of application pro- haust temperature comparator because the value is
grams written to perform the exhaust temperature not affected by extremes that may be the result of
control and monitoring functions such as digital and faulty instrumentation. The temperature–control–
analog input scan. A major function is the exhaust command program in <RST> compares the exhaust
temperature control, which consists of the following temperature control setpoint (calculated in the tem-
programs: perature–control–bias program and stored in the
computer memory) TTRXB to the TTXM value to
1. Temperature control command determine the temperature error. The software pro-
2. Temperature control bias calculations gram converts the temperature error to a fuel stroke
reference signal, FSRT.
3. Temperature reference selection
The temperature control software determines the Temperature Control Bias Program
cold junction compensated thermocouple readings,
selects the temperature control setpoint, calculates Gas turbine firing temperature is determined by the
the control setpoint value, calculates the representa- measured parameters of exhaust temperature and
FUNDAMENTALS OF SPEEDTRONIC 10 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

<RST>
.
TO
COMBUSTION
TTXDR TTXD2 MONITOR

TTXDS SORT
HIGHEST
TO
TTXDT LOWEST

REJECT REJECT
HIGH AVERAGE TTXM
LOW
TC’s AND REMAINING
QUANTITY LOW
OF TC’s USED

<RST> <RST>

TEMPERATURE TEMPERATURE CONTROL

CORNER CONTROL
REFERENCE
FSRMIN
CPD
FSRMAX
SLOPE
TTRXB
MIN MEDIAN
SELECT SELECT FSRT
SLOPE
TTXM
+
FSR +

GAIN
CORNER
FSR
ISOTHERMAL

id0032V

Figure 9 Temperature Control Schematic

compressor discharge pressure (CPD) or exhaust

temperature and fuel consumption (proportional to DIGITAL
COMPUTER
INPUT
FSR). In the computer, firing temperature is limited DATA MEMORY

by a linearized function of exhaust temperature and

CPD backed up by a linearized function of exhaust
temperature and FSR (See Figure 8). The tempera- SELECTED TEMPERATURE
ture control bias program (Figure 10) calculates the TEMPERATURE CONTROL COMPUTER
REFERENCE BIAS MEMORY
TABLE
exhaust temperature control setpoint TTRXB based PROGRAM

on the CPD data stored in computer memory and

constants from the selected temperature–reference
table. The program calculates another setpoint based CONSTANT
STORAGE
on FSR and constants from another temperature–
id0023
reference table.
Figure 10 Temperature Control Bias
Figure 11 is a graphical illustration of the control set- perature setpoint. The constants TTKn_K (FSR bias
points. The constants TTKn_C (CPD bias corner) corner) and TTKn_M (FSR bias slope) are used with
and TTKn_S (CPD bias slope) are used with the the FSR data to determine the FSR bias exhaust tem-
CPD data to determine the CPD bias exhaust tem- perature setpoint. The values for these constants are
Fund_Mk_VI 11 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

given in the Control Specifications–Control System Temperature Reference Select Program

Settings drawing. The temperature–control–bias
program also selects the isothermal setpoint
TTKn_I. The program selects the minimum of the The exhaust temperature control function selects
three setpoints, CPD bias, FSR bias, or isothermal control setpoints to allow gas turbine operation at
for the final exhaust temperature control reference. various firing temperatures. The temperature–refer-
During normal operation with gas or light distillate ence–select program (Figure 12) determines the op-
fuels, this selection results in a CPD bias control erational level for control setpoints based on digital
with an isothermal limit, as shown by the heavy lines input information representing temperature control
on Figure 11. The CPD bias setpoint is compared requirements. Three digital input signals are de-
with the FSR bias setpoint by the program and an coded to select one set of constants which define the
alarm occurs when the CPD setpoint is higher. For control setpoints necessary to meet those require-
units operating with heavy fuel, FSR bias control ments. A typical digital signal is “BASE SELECT”,
will be selected to minimize the effect of turbine selected by clicking on the appropriate target on the
nozzle plugging on firing temperature. The FSR bias operator interface <HMI>.
setpoint will then be compared with the CPD bias
setpoint and an alarm will occur when the FSR set-
point exceeds the CPD setpoint. A ramp function is FUEL CONTROL SYSTEM
provided in the program to limit the rate at which the
setpoint can change. The maximum and minimum The gas turbine fuel control system will change fuel
change in ramp rates (slope) are programmed in flow to the combustors in response to the fuel stroke
constants TTKRXR1 and TTKRXR2. Consult the reference signal (FSR). FSR actually consists of two
Control Sequence Program (CSP) and the Control separate signals added together, FSR1 being the
Specifications drawing for the block diagram il- called–for liquid fuel flow and FSR2 being the
lustration of this function and the value of the called–for gas fuel flow; normally, FSR1 + FSR2 =
constants. Typical rate change limit is 1.5°F per se- FSR. Standard fuel systems are designed for opera-
cond. The output of the ramp function is the exhaust tion with liquid fuel and/or gas fuel. This chapter
temperature control setpoint which is stored in the will describe a dual fuel system. It starts with the ser-
computer memory. vo drive system, where the setpoint is compared
with the feedback signal and converted to a valve
position. It will describe liquid, gas and dual fuel op-
eration and how the FSR from the control systems
previously described is conditioned and sent as a set
point to the servo system.
EXHAUST TEMPERATURE

TTKn_K
TTKn_I ISOTHERMAL

TTKn_C

TEMPERATURE SELECTED
DIGITAL REFERENCE TEMPERATURE
INPUT DATA SELECT REFERENCE
TABLE

CONSTANT
CPD STORAGE
FSR
id0054
id0106
Figure 11 Exhaust Temperature Control Setpoints
Figure 12 Temperature Reference Select Program

FUNDAMENTALS OF SPEEDTRONIC 12 Fund_Mk_VI

MARK VI CONTROL SYSTEM
 GE Power Systems

Servo Drive System actuator. If the hydraulic actuator has spring return,
hydraulic oil will be ported to one side of the cylin-
The heart of the fuel system is a three coil electro– der and the other to drain. A feedback signal pro-
hydraulic servovalve (servo) as shown in Figure 13. vided by a linear variable differential transformer
The servovalve is the interface between the electri- (LVDT, Figure 13) will tell the control whether or
cal and mechanical systems and controls the direc- not it is in the required position. The LVDT outputs
tion and rate of motion of a hydraulic actuator based an AC voltage which is proportional to the position
on the input current to the servo. of the core of the LVDT. This core in turn is con-
nected to the valve whose position is being con-
3-COIL TORQUE MOTOR
trolled; as the valve moves, the feedback voltage
TORQUE changes. The LVDT requires an exciter voltage
MOTOR TORQUE
ARMATURE MOTOR which is provided by the VSVO card.
N N

Figure 14 shows the major components of the servo

JET TUBE
FORCE
positioning loops. The digital (microprocessor sig-
FEEDBACK
SPRING
S S
nal) to analog conversion is done on the VSVO card;
FAIL
this represents called–for fuel flow. The called–for
SAFE
BIAS fuel flow signal is then compared to a feedback rep-
SPRING
resenting actual fuel flow. The difference is ampli-
fied on the VSVO card and sent through the TSVO

Â
P R P card to the servo. This output to the servos is moni-
1 2 tored and there will be an alarm on loss of any one of
the three signals from <RST>.
SPOOL VALVE FILTER
DRAIN PS

1350 PSI Liquid Fuel Control

HYDRAULIC
The liquid fuel system consists of fuel handling
ACTUATOR
components and electrical control components.
Some of the fuel handling components are: primary
TO <RST> LVDT
fuel oil filter, fuel oil stop valve, three fuel pumps,
ABEX Servovalve id0029 fuel bypass valve, fuel pump pressure relief valve,
Figure 13 Electrohydraulic Servovalve flow divider, combined selector valve/pressure
The servovalve contains three electrically isolated gauge assembly, false start drain valve, fuel lines,
coils on the torque motor. Each coil is connected to and fuel nozzles. The electrical control components
one of the three Controllers <RST>. This provides are: liquid fuel pressure switch (upstream) 63FL–2,
redundancy should one of the Controllers or coils fuel oil stop valve limit switch 33FL, liquid fuel
fail. There is a null–bias spring which positions the pump bypass valve servovalve 65FP, flow divider
servo so that the actuator will go to the fail safe posi- magnetic speed pickups 77FD–1, –2, –3 and
tion should ALL power and/or control signals be SPEEDTRONIC control cards TSVO and VSVO. A
lost. diagram of the system showing major components is
shown in Figure 15.
If the hydraulic actuator is a double–action piston,
the control signal positions the servovalve so that it The fuel bypass valve is a hydraulically actuated
ports high–pressure oil to either side of the hydraulic valve with a linear flow characteristic. Located

Fund_Mk_VI 13 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
MARK VI CONTROL SYSTEM
FUNDAMENTALS OF SPEEDTRONIC

POSTION FEEDBACK
LVDT
<R>

TSVO VSVO TSVO

3.2KHZ
EXCITATION
REF
D/A
Figure 14 Servo Positioning Loops

FUEL

<S>
SERVO
VSVO 3.2KHZ VALVE

REF
D/A TORQUE
MOTOR
14

HYDRAULIC
ACTUATOR

HIGH
<T> PRESSURE
OIL
VSVO 3.2KHZ
EXCITATION
REF
D/A

GE Power Systems
POSTION FEEDBACK
LVDT
Fund_Mk_VI

id0026
 GE Power Systems

between the inlet (low pressure) and discharge (high fuel necessary to meet the control system fuel de-
pressure) sides of the fuel pump, this valve bypasses mand. It is positioned by servo valve 65FP, which
excess fuel delivered by the fuel pump back to the receives its signal from the controllers.
fuel pump inlet, delivering to the flow divider the

<RST>

FSR1 FQ1 <RST>

FQROUT <RST>
TSVO
TNH
L4 VSVO
L20FLX PR/A

BY-PASS VALVE ASM.

P R 65FP TYPICAL
40µ DIFFERENTIAL FLOW FUEL NOZZLES
PRESSURE GUAGE DIVIDER
77FD-1
63FL-2 OH
HYDRAULIC COMBUSTION
SUPPLY CHAMBER
OFV

FUEL
STOP
VALVE VR4
OF AD

FUEL PUMP
(QTY 3)
33FL
M FALSE START
OLT- DRAIN VALVE
CONTROL CHAMBER OFD
OIL 77FD-2
TO DRAIN
77FD-3

id0031V

Figure 15 Liquid Fuel Control Schematic

The flow divider divides the single stream of fuel VSVO card modulates servovalve 65FP based on
from the pump into several streams, one for each inputs of turbine speed, FSR1 (called–for liquid fuel
combustor. It consists of a number of matched high flow), and flow divider speed (FQ1).
volumetric efficiency positive displacement gear
pumps, again one per combustor. The flow divider is Fuel Oil Control – Software
driven by the small pressure differential between the
When the turbine is run on liquid fuel oil, the control
inlet and outlet. The gear pumps are mechanically
system checks the permissives L4 and L20FLX and
connected so that they all run at the same speed,
does not allow FSR1 to close the bypass valve unless
making the discharge flow from each pump equal.
they are ‘true’ (closing the bypass valve sends fuel to
Fuel flow is represented by the output from the flow
the combustors). The L4 permissive comes from the
divider magnetic pickups (77FD–1, –2 & –3). These
Master Protective System (to be discussed later) and
are non–contacting magnetic pickups, giving a
L20FLX becomes ‘true’ after the turbine vent timer
pulse signal frequency proportional to flow divider
times out. These signals control the opening and
speed, which is proportional to the fuel flow deliv-
closing of the fuel oil stop valve.
ered to the combustion chambers.
The FSR signal from the controlling system goes
The TSVO card receives the pulse rate signals from through the fuel splitter where the liquid fuel re-
77FD–1, –2, and –3 and outputs an analog signal quirement becomes FSR1. The FSR1 signal is mul-
which is proportional to the pulse rate input. The tiplied by TNH, so fuel flow becomes a function of
Fund_Mk_VI 15 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

speed – an important feature, particularly while the Gas Fuel Control

unit is starting. This enables the system to have bet-
ter resolution at the lower, more critical speeds The dry low NOx II (DLN–2) control system regu-
where air flow is very low. This produces the lates the distribution of gas fuel to a multi–nozzle
FQROUT signal, which is the digital liquid fuel combustor arrangement. The fuel flow distribution
flow command. At full speed TNH does not change, to each fuel nozzle assembly is a function of com-
therefore FQROUT is directly proportional to FSR. bustion reference temperature (TTRF1) and IGV
temperature control mode. By a combination of fuel
FQROUT then goes to the VSVO card where it is staging and shifting of combustion modes from dif-
changed to an analog signal to be compared to the fusion at ignition through premix at higher loads,
feedback signal from the flow divider. As the fuel low nitrous oxide (NOx) emissions are achieved.
flows into the turbine, speed sensors 77FD–1, –2, Fuel gas is controlled by the gas stop/speed ratio
and –3 send a signal to the TSVO card, which in turn valve (SRV), the primary, secondary and quaternary
outputs the fuel flow rate signal (FQ1) to the VSVO gas control valves (GCV) , and the premix splitter
card. When the fuel flow rate is equal to the called– valve (PMSV). The premix splitter valve controls
for rate (FQ1 = FSR1), the servovalve 65FP is the split between secondary and tertiary gas flow.
moved to the null position and the bypass valve re- All valves are servo controlled by signals from the
mains “stationary” until some input to the system SPEEDTRONIC control panel (Figure 16).
changes. If the feedback is in error with FQROUT,
the operational amplifier on the VSVO card will It is the gas control valve which controls the desired
change the signal to servovalve 65FP to drive the by- gas fuel flow in response to the command signal
pass valve in a direction to decrease the error. FSR. To enable it to do this in a predictable manner,
the speed ratio valve is designed to maintain a prede-
The flow divider feedback signal is also used for termined pressure (P2) at the inlet of the gas control
valve as a function of gas turbine speed.
system checks. This analog signal is converted to
digital counts and is used in the controller’s software There are three main DLN–2 combustion modes:
to compare to certain limits as well as to display fuel Primary, Lean–Lean, and Premix.
flow on the <HMI>. The checks made are as fol-
Primary mode exists from light off to 81% corrected
lows:
speed, fuel flow to primary nozzles only. Lean–
Lean is from 81% corrected speed to a preselected
L60FFLH:Excessive fuel flow on start–up combustion reference temperature, with fuel to the
primary and tertiary nozzles. In Premix operation
L3LFLT1:Loss of LVDT position feedback
fuel is directed to secondary, tertiary and quaternary
nozzles. Minimum load for this operation is set by
L3LFBSQ:Bypass valve is not fully open when
combustion reference temperature and IGV posi-
the stop valve is closed.
tion.
L3LFBSC:Servo current is detected when the The fuel gas control system consists primarily of the
stop valve is closed. following components: gas strainer, gas supply
pressure switch 63FG, stop/speed ratio valve assem-
L3LFT:Loss of flow divider feedback bly, fuel gas pressure transducer(s) 96FG, gas fuel
vent solenoid valve 20VG, control valve assembly,
If L60FFLH is true for a specified time period (nom- LVDT’s 96GC–1, –2, –3, –4, –5, –6, 96SR–1, –2, 96
inally 2 seconds), the unit will trip; if L3LFLT1 PS–1, –2, electro–hydraulic servovalves 90SR,
through L3LFT are true, these faults will trip the unit 65GC and 65PS, dump valve(s) VH–5, three pres-
during start–up and require manual reset. sure gauges, gas manifold with ‘pigtails’ to respec-
FUNDAMENTALS OF SPEEDTRONIC 16 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

tive fuel nozzles, and SPEEDTRONIC control cards tion is contained in subsequent para-
TBQB and TCQC. The components are shown graphs.
schematically in Figure 17. A functional explana-

DLN–2 GAS FUEL SYSTEM

SGCV T

SRV PMSV S SINGLE

PGCV
BURNING
ZONE
P 5 BURNERS

QGCV
*
Q
GAS SKID TURBINE COMPARTMENT

SRV SPEED/RATIO VALVE T TERTIARY MANIFOLD, 1 NOZ. PREMIX ONLY

PGCV GAS CONTROL, PRIMARY S SECONDARY MANIFOLD, 4 NOZ. PREMIX INJ.
SGCV GAS CONTROL, SECONDARY P PRIMARY MANIFOLD, 4 NOZ. DIFFUSION INJ.
QGCV GAS CONTROL, QUATERNARY Q QUAT MANIFOLD, CASING. PREMIX ONLY
PMSV PREMIX SPLITTER VALVE
* PURGE AIR (PCD AIR SUPPLY)

Figure 16 DLN–2 Gas Fuel System

Fund_Mk_VI 17 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
 GE Power Systems

VSVO
FPRG TSVO POS1 VSVO TSVO

POS2 GAS CONTROL GAS CONTROL

SPEED RATIO FSR2 VALVE SERVO VALVE POSITION
VALVE CONTROL FEEDBACK

FPG

TBAI 96FG-2A TSVO

VAIC
96FG-2B
96FG-2C 20VG
TRANSDUCERS

VENT

COMBUSTION
CHAMBER

63FG-3
STOP/ GAS
RATIO CONTROL
VALVE VALVE

GAS
P2

Electrical
Connection GAS
MANIFOLD
Hydraulic LVDT’S LVDT’S
Piping 96SR-1,2 96GC-1,2

Gas Piping
VH5-1 DUMP
RELAY
TRIP

90SR SERVO
65GC SERVO

HYDRAULIC
SUPPLY id0059V

Figure 17 Gas Fuel Control System

FUNDAMENTALS OF SPEEDTRONIC 18 Fund_Mk_VI

MARK VI CONTROL SYSTEM
 GE Power Systems

Gas Control Valves then output to the servo valve through the TSVO
The position of the gas control valve plug is intended card. The gas control valve stem position is sensed
to be proportional to FSR2 which represents called– by the output of a linear variable differential trans-
for gas fuel flow. Actuation of the spring–loaded gas former (LVDT) and fed back through the TSVO card
control valve is by a hydraulic cylinder controlled by to an operational amplifier on the VSVO card where
an electro–hydraulic servovalve. it is compared to the FSROUT input signal at a sum-
ming junction. There are two LVDTs providing
When the turbine is to run on gas fuel the permis- feedback ; two of the three controllers are dedicated
sives L4, L20FGX and L2TVX (turbine purge com- to one LVDT each, while the third selects the highest
plete) must be ‘true’, similar to the liquid system. feedback through a high–select diode gate. If the
This allows the Gas Control Valve to open. The feedback is in error with FSROUT, the operational
stroke of the valve will be proportional to FSR. amplifier on the VSVO card will change the signal
FSR goes through the fuel splitter (to be discussed in to the hydraulic servovalve to drive the gas control
the dual fuel section) where the gas fuel requirement valve in a direction to decrease the error. In this way
becomes FSR2, which is then conditioned for offset the desired relationship between position and FSR2
and gain. This signal, FSROUT, goes to the VSVO is maintained and the control valve correctly meters
card where it is converted to an analog signal and the gas fuel. See Figure 18.
<RST>

OFFSET

GAIN
<RST>
FSR2 +
TBQC
+
HIGH
SELECT
L4

L3GCV
FSROUT

ANALOG
I/O

GAS CONTROL VALVE

GAS
P2

ÎÎ
GAS CONTROL VALVE
POSITION LOOP

ÎÎ
CALIBRATION

ÎÎ
POSITION
LVDT

LVDT’S
ELECTRICAL CONNECTION 96GC-1, -2

GAS PIPING
SERVO
HYDRAULIC PIPING VALVE FSR

id0027V

Figure 18 Gas Control Valve Control Schematic

Fund_Mk_VI 19 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
 GE Power Systems

<RST>
TNH

<RST>
GAIN
VSVO

+ FPRG
OFFSET + D
A
L4
FPG
L3GRV

HIGH POS2
SELECT

96FG-2A
96FG-2B
96FG-2C
SPEED RATIO VALVE

GAS
VAIC

ÎÎÎ
96SR-1,2
LVDT’S

OPERATING
CYLINDER
PISTON
ÎÎÎ
ÎÎÎ TBAI

TRIP OIL DUMP

RELAY
TSVO

SERVO
VALVE
LEGEND
HYDRAULIC
ELECTRICAL OIL
CONNECTION
GAS PIPING
HYDRAULIC
PIPING P2
DIGITAL or PRESSURE
CONTROL VOLTAGE

TNH
Speed Ratio Valve Pressure Calibration
id0058V

Figure 19 Stop/Speed Ratio Valve Control Schematic

FUNDAMENTALS OF SPEEDTRONIC 20 Fund_Mk_VI

MARK VI CONTROL SYSTEM
 GE Power Systems

The plug in the gas control valve is contoured to pro- The stop/speed ratio valve provides a positive stop
vide the proper flow area in relation to valve stroke. to fuel gas flow when required by a normal shut–
The gas control valve uses a skirted valve disc and down, emergency trip, or a no–run condition. Hy-
venturi seat to obtain adequate pressure recovery. draulic trip dump valve VH–5 is located between the
High pressure recovery occurs at overall valve pres- electro–hydraulic servovalve 90SR and the hydrau-
sure ratios substantially less than the critical pres- lic actuating cylinder. This dump valve is operated
sure ratio. The net result is that flow through the by the low pressure control oil trip system. If permis-
control valve is independent of valve pressure drop. sives L4 and L3GRV are ‘true’ the trip oil (OLT) is at
Gas flow then is a function of valve inlet pressure P2 normal pressure and the dump valve is maintained in
and valve area only. a position that allows servovalve 90SR to control the
cylinder position. When the trip oil pressure is low
As before, an open or a short circuit in one of the ser- (as in the case of normal or emergency shutdown),
vo coils or in the signal to one coil does not cause a the dump valve spring shifts a spool valve to a posi-
trip. Each GCV has two LVDTs and can run correct- tion which dumps the high pressure hydraulic oil
ly on one. (OH) in the speed ratio/stop valve actuating cylinder
to the lube oil reservoir. The closing spring atop the
valve plug instantly shuts the valve, thereby shutting
Stop/Speed Ratio Valve off fuel flow to the combustors.
In addition to being displayed, the feedback signals
The speed ratio/stop valve is a dual function valve. It and the control signals of both valves are compared
serves as a pressure regulating valve to hold a de- to normal operating limits, and if they go outside of
sired fuel gas pressure ahead of the gas control valve these limits there will be an alarm. The following are
and it also serves as a stop valve. As a stop valve it is typical alarms:
an integral part of the protection system. Any emer-
gency trip or normal shutdown will move the valve L60FSGH: Excessive fuel flow on start–up
to its closed position shutting off gas fuel flow to the L3GRVFB: Loss of LVDT feedback on the SRV
turbine. This is done either by dumping hydraulic oil
L3GRVO: SRV open prior to permissive to open
from the Stop/Speed Ratio Valve VH–5 hydraulic
trip relay or driving the position control closed elec- L3GRVSC: Servo current to SRV detected prior
trically. to permissive to open
L3GCVFB: Loss of LVDT feedback on the
The stop/speed ratio valve has two control loops. GCV
There is a position loop similar to that for the gas
control valve and there is a pressure control loop. L3GCVO: GCV open prior to permissive to
See Figure 19. Fuel gas pressure P2 at the inlet to the open
gas control valve is controlled by the pressure loop L3GCVSC: Servo current to GCV detected
as a function of turbine speed. This is done by pro- prior to permissive to open
portioning it to turbine speed signal TNH, with an
L3GFIVP: Intervalve (P2) pressure low
offset and gain, which then becomes Gas Fuel Pres-
sure Reference FPRG. FPRG then goes to the The servovalves are furnished with a mechanical
VSVO card to be converted to an analog signal. P2 null offset bias to cause the gas control valve or
pressure is measured by 96FG which outputs a volt- speed ratio valve to go to the zero stroke position
age proportional to P2 pressure. This P2 signal (fail safe condition) should the servovalve signals or
(FPG) is compared to the FPRG and the error signal power be lost. During a trip or no–run condition, a
(if any) is in turn compared with the 96SR LVDT positive voltage bias is placed on the servo coils
feedback to reposition the valve as in the GCV loop. holding them in the ‘valve closed’ position.
Fund_Mk_VI 21 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

Premix Splitter Valve <RST>

FUEL SPLITTER
L84TG
A=B
TOTAL GAS
The Premix splitter valve (PMSV) regulates the split A=B
L84TL
TOTAL LIQUID
MAX. LIMIT
of secondary/tertiary gas fuel flow between the sec-
MIN. LIMIT
ondary and tertiary gas fuel manifolds. The valve is MEDIAN
L83FZ SELECT
referenced to the secondary fuel passages, i.e. 0% PERMISSIVES
valve stroke corresponds to 0% secondary fuel flow. RAMP

Unlike the SRV and GCV’s the flow through the RATE
L83FG
splitter valve is not linear with valve position.The GAS SELECT
L83FL
control system linearizes the fuel split setpoint and LIQUID SELECT
the resulting valve position command FSRXPOUT FSR FSR1
LIQUID REF.
is used as the position reference.
FSR2
GAS REF.
id0034
Dual Fuel Control Figure 20 Fuel Splitter Schematic

Turbines that are designed to operate on both liquid Fuel Transfer – Liquid to Gas
and gaseous fuel are equipped with controls to pro-
vide the following features:
If the unit is running on liquid fuel (FSR1) and the
1.Transfer from one fuel to the other on com- “GAS” target on the <HMI> screen is selected the
mand. following sequence of events will take place, pro-
viding the transfer and fuel gas permissives are true
2. Allow time for filling the lines with the type of (refer to Figure 21):
fuel to which turbine operation is being trans-
ferred. FSR1 will remain at its initial value, but FSR2 will
step to a value slightly greater than zero, usually
3. Operation of liquid fuel nozzle purge when 0.5%. This will open the gas control valve slightly to
operating totally on gas fuel. bleed down the intervalve volume. This is done in
case a high pressure has been entrained. The pres-
4. Operation of gas fuel nozzle purge when oper-
ence of a higher pressure than that required by the
ating totally on liquid fuel.
speed/ratio controller would cause slow response in
The software diagram for the fuel splitter is shown in initiating gas flow.
Figure 20.
After a typical time delay of thirty seconds to bleed
down the P2 pressure and fill the gas supply line, the
Fuel Splitter software program ramps the fuel commands, FSR2
to increase and FSR1 to decrease, at a programmed
As stated before FSR is divided into two signals, rate through the median select gate. This is complete
FSR1 and FSR2, to provide dual fuel operation. See in thirty seconds.
Figure 20.
When the transfer is complete logic signal L84TG
FSR is multiplied by the liquid fuel fraction FX1 to (Total Gas) will de–energize the liquid fuel forward-
produce the FSR1 signal. FSR1 is then subtracted ing pump, close the fuel oil stop valve by de–ener-
from the FSR signal resulting in FSR2, the control gizing the liquid fuel dump valve 20FL, and initiate
signal for the secondary fuel. the purge sequence.
FUNDAMENTALS OF SPEEDTRONIC 22 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

Fuel Transfer – Gas to Liquid

Transfer from Full Gas to Full Distillate
FSR2 Transfer from gas to liquid is essentially the same se-
quence as previously described, except that gas and
UNITS

liquid fuel command signals are interchanged. For

FSR1

PURGE
instance, at the beginning of a transfer, FSR2 re-
SELECT DISTILLATE
TIME
mains at its initial value, but FSR1 steps to a value
slightly greater than zero. This will command a
Transfer from Full Distillate to Full Gas
small liquid fuel flow. If there has been any fuel leak-
FSR1
age out past the check valves, this will fill the liquid
fuel piping and avoid any delay in delivery at the be-
UNITS

ginning of the FSR1 increase.

FSR2
The rest of the sequence is the same as liquid–to–
PURGE
TIME
SELECT GAS gas, except that there is usually no purging se-
quence.
Transfer from Full Distillate to Mixture
Gas Fuel Purge
FSR1
UNITS

Primary gas fuel purge is required during premix

steady state and liquid fuel operation. This system
FSR2

PURGE
involves a double block and bleed arrangement,
TIME
SELECT GAS SELECT MIX wherby two purge valves (VA13–1, –2) are shut
id0033
when primary gas is flowing and intervalve vent so-
Figure 21 Fuel Transfer lenoid (20VG–2) is open to bleed any leakage across
the valves. The purge valves are air operated through
solenoid valves 20PG–1, –2. When there is no pri-
Liquid Fuel Purge mary gas flow, the purge valves open and allow com-
pressor discharge air to flow through the primary
fuel nozzle passages. Secondary purge is required
To prevent coking of the liquid fuel nozzles while for the secondary and tertiary nozzles when second-
operating on gas fuel, some atomizing air is diverted ary and tertiary fuel flow is reduced to zero and when
through the liquid fuel nozzles. The following se- operating on liquid fuel. This is a block and bleed ar-
quence of events occurs when transfer from liquid to rangement similar to the primary purge with two
gas is complete. purge valves (VA13–3, –4), intervalve vent solenoid
(20VG–3), and solenoid valves 20PG–3, –4.
Air from the atomizing air system flows through a
cooler (HX4–1), through the fuel oil purge valve
(VA19–3) and through check valve VCK2 to each
fuel nozzle.
MODULATED INLET GUIDE VANE
The fuel oil purge valve is controlled by the position SYSTEM
of a solenoid valve 20PL–2 . When this valve is en-
ergized , actuating air pressure opens the purge oil The Inlet Guide Vanes (IGVs) modulate during the
check valve, allowing air flow to the fuel oil nozzle acceleration of the gas turbine to rated speed, load-
purge check valves. ing and unloading of the generator, and deceleration
of the gas turbine. This IGV modulation maintains
proper flows and pressures, and thus stresses, in the
Fund_Mk_VI 23 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

compressor, maintains a minimum pressure drop bined cycle application, maintains high exhaust
across the fuel nozzles, and, when used in a com- temperatures at low loads.

<RST>
<RST>
CSRGV
VSVO
CSRGV IGV REF CSRGVOUT
D/A

HIGH
SELECT

TSVO

CLOSE

HM3-1

HYD.
SUPPLY R P OPEN
IN FH6 OUT
–1

90TV-1
2 1
A
96TV-1,2
OLT-1
TRIP OIL
C1

VH3-1
D C2
ORIFICES (2)

OD
id0030

Figure 23 Modulating Inlet Guide Vane Control Schematic

Guide Vane Actuation Operation

During start–up, the inlet guide vanes are held fully

The modulated inlet guide vane actuating system is closed, a nominal 27 degree angle, from zero to
comprised of the following components: servovalve 83.5% corrected speed. Turbine speed is corrected
90TV, LVDT position sensors 96TV–1 and to reflect air conditions at 27° C (80° F); this com-
96TV–2, and, in some instances, solenoid valve pensates for changes in air density as ambient condi-
20TV and hydraulic dump valve VH3. Control of tions change. At ambient temperatures greater than
90TV will port hydraulic pressure to operate the 80° F, corrected speed TNHCOR is less than actual
variable inlet guide vane actuator. If used, 20TV and speed TNH; at ambients less than 27° C (80° F),
VH3 can prevent hydraulic oil pressure from flow- TNHCOR is greater than TNH. After attaining a
ing to 90TV. See Figure 23. speed of approximately 83.5%, the guide vanes will
FUNDAMENTALS OF SPEEDTRONIC 24 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

modulate open at about 6.7 degrees per percent in-

crease in corrected speed. When the guide vanes FULL OPEN (MAX ANGLE)

reach the minimum full speed angle, nominally 54°,

IGV ANGLE – DEGREES (CSRGV)

they stop opening; this is usually at approximately
91% TNH. By not allowing the guide vanes to close SIMPLE CYCLE
COMBINED
CYCLE
(CSKGVSSR) (TTRX)
to an angle less than the minimum full speed angle at
100% TNH, a minimum pressure drop is maintained MINIMUM FULL SPEED ANGLE
across the fuel nozzles, thereby lessening combus- ROTATING
STALL STARTUP
tion system resonance. Solenoid valve 20CB is usu- REGION PROGRAM

ally opened when the generator breaker is closed; REGION OF NEGATIVE

5TH STAGE EXTRACTION
this in turn closes the compressor bleed valves. FULL CLOSED
(MIN ANGLE)
PRESSURE

0 100
As the unit is loaded and exhaust temperature in- CORRECTED SPEED–%
(TNHCOR) 0 100
LOAD–%
creases, the inlet guide vanes will go to the full open FSNL BASE LOAD
EXHAUST TEMPERATURE
position when the exhaust temperature reaches one id0037

of two points, depending on the operation mode se- Figure 24 Variable Inlet Guide Vane Schedule
lected. For simple cycle operation, the IGVs move to
the full open position at a pre–selected exhaust tem-
perature, usually 371° C (700° F). For combined PROTECTION SYSTEMS
cycle operation, the IGVs begin to move to the full
open position as exhaust temperature approaches The gas turbine protection system is comprised of a
the temperature control reference temperature; nor- number of sub–systems, several of which operate
mally, the IGVs begin to open when exhaust temper- during each normal start–up and shutdown. The oth-
ature is within 17° C (30° F) of the temperature er systems and components function strictly during
control reference. emergency and abnormal operating conditions. The
most common kind of failure on a gas turbine is the
During a normal shutdown, as the exhaust tempera- failure of a sensor or sensor wiring; the protection
ture decreases the IGVs move to the minimum full systems are set up to detect and alarm such a failure.
speed angle; as the turbine decelerates from 100% If the condition is serious enough to disable the
TNH, the inlet guide vanes are modulated to the ful- protection completely, the turbine will be tripped.
ly closed position. When the generator breaker Protective systems respond to the simple trip signals
opens, the compressor bleed valves will be opened. such as pressure switches used for low lube oil pres-
sure, high gas compressor discharge pressure, or
In the event of a turbine trip, the compressor bleed similar indications. They also respond to more com-
valves are opened and the inlet guide vanes go to the plex parameters such as overspeed, overtempera-
fully closed position. The inlet guide vanes remain ture, high vibration, combustion monitor, and loss of
fully closed as the turbine continues to coast down. flame. To do this, some of these protection systems
and their components operate through the master
For underspeed operation, if TNHCOR decreases control and protection circuit in the SPEEDTRON-
below approximately 91%, the inlet guide vanes IC control system, while other totally mechanical
modulate closed at 6.7 degrees per percent decrease systems operate directly on the components of the
in corrected speed. In most cases, if the actual speed turbine. In each case there are two essentially inde-
decreases below 95% TNH, the generator breaker pendent paths for stopping fuel flow, making use of
will open and the turbine speed setpoint will be reset both the fuel control valve (FCV) and the fuel stop
to 100.3%. The IGVs will then go to the minimum valve (FSV). Each protective system is designed in-
full speed angle. See Figure 24. dependent of the control system to avoid the possi-
Fund_Mk_VI 25 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

bility of a control system failure disabling the

protective devices. See Figure 25.

MASTER
PRIMARY PROTECTION GCV GAS FUEL
OVERSPEED CIRCUIT SERVOVALVE CONTROL VALVE
<RST>

OVERTEMP

SRV GAS FUEL

VIBRATION SERVOVALVE SPEED RATIO/
STOP VALVE

COMBUSTION
MONITOR
RELAY
VOTING 20FG
MODULE
LOSS
of
FLAME

MASTER
PROTECTION
SECONDARY CIRCUIT BYPASS
<XYZ> VALVE
OVERSPEED FUEL
SERVOVALVE PUMP

RELAY LIQUID
VOTING 20FL FUEL STOP
MODULE VALVE

id0036V

Figure 25 Protective Systems Schematic

Trip Oil Inlet Orifice

An orifice is located in the line running from the

A hydraulic trip system called Trip Oil is the primary bearing header supply to the trip oil system. This ori-
protection interface between the turbine control and fice is sized to limit the flow of oil from the lube oil
protection system and the components on the tur- system into the trip oil system. It must ensure ade-
bine which admit, or shut–off, fuel. The system con- quate capacity for all tripping devices, yet prevent
tains devices which are electrically operated by reduction of lube oil flow to the gas turbine and other
SPEEDTRONIC control signals as well as some to- equipment when the trip system is in the tripped
tally mechanical devices. state.

Besides the tripping functions, trip oil also provides Dump Valve
a hydraulic signal to the fuel stop valves for normal
start–up and shutdown sequences. On gas turbines Each individual fuel branch in the trip oil system has
equipped for dual fuel (gas and oil) operation the a solenoid dump valve (20FL for liquid, 20FG for
system is used to selectively isolate the fuel system gas). This device is a solenoid–operated spring–re-
not required. turn spool valve which will relieve trip oil pressure
only in the branch that it controls. These valves are
Significant components of the Hydraulic Trip Cir- normally energized–to–run, deenergized–to–trip.
cuit are described below. This philosophy protects the turbine during all nor-
FUNDAMENTALS OF SPEEDTRONIC 26 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

mal situations as well as that time when loss of dc

power occurs.

PROTECTIVE MASTER
SIGNALS PROTECTION
L4
CIRCUITS
LIQUID
FUEL
LIQUID FUEL
STOP VALVE
20FG 20FL

ORIFICE AND
CHECK VALVE
NETWORK
63HL

INLET ORIFICE

GAS FUEL
GAS SPEED RATIO/
FUEL STOP VALVE

WIRING 63HG

PIPING

GAS FUEL
DUMP RELAY
VALVE
OH
id0056

Figure 26 Trip Oil Schematic – Dual Fuel

Check Valve & Orifice Network dividual fuel stop valve may be selectively closed by
dumping the flow of trip oil going to it. Solenoid
At the inlet of each individual fuel branch is a check valve 20FL can cause the trip valve on the liquid fuel
valve and orifice network which limits flow out of stop valve to go to the trip state, which permits clo-
that branch. This network limits flow into each sure of the liquid fuel stop valve by its spring return
branch, thus allowing individual fuel control with- mechanism. Solenoid valve 20FG can cause the trip
out total system pressure decay. However, when one valve on the gas fuel speed ratio/stop valve to go to
of the trip devices located in the main artery of the the trip state, permitting its spring–returned closure.
system, e.g., the overspeed trip, is actuated, the The orifice in the check valve and orifice network
check valve will open and result in decay of all trip permits independent dumping of each fuel branch of
pressures. the trip oil system without affecting the other
branch. Tripping all devices other than the individu-
Pressure Switches al dump valves will result in dumping the total trip
oil system, which will shut the unit down.
Each individual fuel branch contains pressure
switches (63HL–1,–2,–3 for liquid, 63HG–1,–2,–3 During start–up or fuel transfer, the SPEEDTRON-
for gas) which will ensure tripping of the turbine if IC control system will close the appropriate dump
the trip oil pressure becomes too low for reliable op- valve to activate the desired fuel system(s). Both
eration while operating on that fuel. dump valves will be closed only during fuel transfer
or mixed fuel operation.
Operation
The dump valves are de–energized on a “2–out–
The tripping devices which cause unit shutdown or of–3 voted” trip signal from the relay module. This
selective fuel system shutdown do so by dumping helps prevent trips caused by faulty sensors or the
the low pressure trip oil (OLT). See Figure 26. An in- failure of one controller.
Fund_Mk_VI 27 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

The signal to the fuel system servovalves will also <RST> <XYZ>
HIGH PRESSURE OVERSPEED TRIP
be a “close” command should a trip occur. This is
TNH HP SPEED
done by clamping FSR to zero. Should one control- A
A>B
L12H TO MASTER
PROTECTION
TRIP SETPOINT SET
ler fail, the FSR from that controller will be zero. TNKHOS B AND
AND ALARM
MESSAGE
LATCH
The output of the other two controllers is sufficient TNKHOST
TEST

to continue to control the servovalve. TEST

RESET
LH3HOST PERMISSIVE

By pushing the Emergency Trip Button, 5E P/B, the L86MR1 MASTER RESET

P28 vdc power supply is cut off to the relays control- SAMPLING RATE = 0.25 SEC

ling solenoid valves 20FL and 20FG, thus de–ener- id0060

gizing the dump valves. Figure 27 Electronic Overspeed Trip

Overtemperature Protection
Overspeed Protection
The overtemperature system protects the gas turbine
The SPEEDTRONIC Mark VI overspeed system is against possible damage caused by overfiring. It is a
designed to protect the gas turbine against possible backup system, operating only after the failure of the
damage caused by overspeeding the turbine rotor. temperature control system.
Under normal operation, the speed of the rotor is
controlled by speed control. The overspeed system TTKOT1 TRIP
would not be called on except after the failure of oth-
er systems.

The overspeed protection system consists of a pri-

EXH TEMP

mary and secondary electronic overspeed system.

The primary electronic overspeed protection system
resides in the <RST> controllers. The secondary TTRX

electronic overspeed protection system resides in TRIP MARGIN

TTKOT2
the <XYZ> controllers (in <VPRO>). Both systems ALARM MARGIN
TTKOT3
consist of magnetic pickups to sense turbine speed,
speed detection software, and associated logic cir- CPD/FSR
id0053
cuits and are set to trip the unit at 110% rated speed.
Figure 29 Overtemperature Protection

Electronic Overspeed Protection System Under normal operating conditions, the exhaust
temperature control system acts to control fuel flow
The electronic overspeed protection function is per- when the firing temperature limit is reached. In cer-
formed in both <RST> and <XYZ> as shown in Fig- tain failure modes however, exhaust temperature
ure 27. The turbine speed signal (TNH) derived from and fuel flow can exceed control limits. Under such
the magnetic pickup sensors (77NH–1,–2, and –3) is circumstances the overtemperature protection sys-
compared to an overspeed setpoint (TNKHOS). tem provides an overtemperature alarm about 14° C
When TNH exceeds the setpoint, the overspeed trip (25° F) above the temperature control reference. To
signal (L12H) is transmitted to the master protective avoid further temperature increase, it starts unload-
circuit to trip the turbine and the “OVERSPEED ing the gas turbine. If the temperature should in-
TRIP” message will be displayed on the <HMI>. crease further to a point about 22° C (40° F) above
This trip will latch and must be reset by the master the temperature control reference, the gas turbine is
reset signal L86MR. tripped. For the actual alarm and trip overtempera-
FUNDAMENTALS OF SPEEDTRONIC 28 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

ture setpoints refer to the Control Specifications. will be tripped through the master protection circuit.
See Figure 29. The trip function will be latched in and the master re-
set signal L86MR1 must be true to reset and unlatch
Overtemperature trip and alarm setpoints are deter-
the trip.
mined from the temperature control setpoints
derived by the Exhaust Temperature Control soft-
ware. See Figure 30. Flame Detection and Protection System

<RST> The SPEEDTRONIC Mark VI flame detectors per-

OVERTEMPERATURE

TTXM
TRIP AND ALARM form two functions, one in the sequencing system
A
ALARM
A>B
L30TXA
ALARM
TO ALARM and the other in the protective system. During a nor-
TTKOT3 B MESSAGE
AND SPEED
SETPOINT mal start–up the flame detectors indicate when a
LOWER
flame has been established in the combustion cham-
TTRXB
bers and allow the start–up sequence to continue.
A
A>B Most units have four flame detectors, some have
TTKOT2 B

OR
two, and a very few have eight. Generally speaking,
A if half of the flame detectors indicate flame and half
A>B
TTKOT1
TRIP ISOTHERMAL
B
SET
AND
L86TXT
TRIP
TO MASTER
PROTECTION
(or less) indicate no–flame, there will be an alarm
LATCH
L86MR1
AND ALARM
MESSAGE but the unit will continue to run. If more than half in-
RESET
SAMPLING RATE: 0.25 SEC. dicate loss–of–flame, the unit will trip on “LOSS OF
id0055
FLAME.” This avoids possible accumulation of an
Figure 30 Overtemperature Trip and Alarm explosive mixture in the turbine and any exhaust
heat recovery equipment which may be installed.
Overtemperature Protection Software The flame detector system used with the SPEED-
TRONIC Mark VI system detects flame by sensing
ultraviolet (UV) radiation. Such radiation results
Overtemperature Alarm (L30TXA)
from the combustion of hydrocarbon fuels and is
The representative value of the exhaust temperature more reliably detected than visible light, which va-
thermocouples (TTXM) is compared with alarm and ries in color and intensity.
trip temperature setpoints. The “EXHAUST TEM- The flame sensor is a copper cathode detector de-
PERATURE HIGH” alarm message will be dis- signed to detect the presence of ultraviolet radiation.
played when the exhaust temperature (TTXM) The SPEEDTRONIC control will furnish +24Vdc
exceeds the temperature control reference (TTRXB) to drive the ultraviolet detector tube. In the presence
plus the alarm margin (TTKOT3) programmed as a of ultraviolet radiation, the gas in the detector tube
Control Constant in the software. The alarm will au- ionizes and conducts current. The strength of the
tomatically reset if the temperature decreases below current feedback (4 – 20 mA) to the panel is a pro-
the setpoint. portional indication of the strength of the ultraviolet
radiation present. If the feedback current exceeds a
Overtemperature Trip (L86TXT) threshold value the SPEEDTRONIC generates a
logic signal to indicate ”FLAME DETECTED” by
An overtemperature trip will occur if the exhaust
the sensor.
temperature (TTXM) exceeds the temperature con-
trol reference (TTRXB) plus the trip margin The flame detector system is similar to other protec-
(TTKOT2), or if it exceeds the isothermal trip set- tive systems, in that it is self–monitoring. For exam-
point (TTKOT1). The overtemperature trip will ple, when the gas turbine is below L14HM all
latch, the “EXHAUST OVERTEMPERATURE channels must indicate “NO FLAME.” If this condi-
TRIP” message will be displayed, and the turbine tion is not met, the condition is annunciated as a
Fund_Mk_VI 29 FUNDAMENTALS OF SPEEDTRONIC
MARK VI CONTROL SYSTEM
 GE Power Systems

“FLAME DETECTOR TROUBLE” alarm and the and the turbine will continue to run. More than half
turbine cannot be started. After firing speed has been the flame detectors must indicate “NO FLAME” in
reached and fuel introduced to the machine, if at order to trip the turbine.
least half the flame detectors see flame the starting
Note that a short–circuited or open–circuited detec-
sequence is allowed to proceed. A failure of one de-
tor tube will result in a “NO FLAME” signal.
tector will be annunciated as “FLAME DETECTOR
TROUBLE” when complete sequence is reached
SPEEDTRONIC Mk VI Flame Detection

Turbine
Protection
Logic

28FD
UV Scanner

28FD
UV Scanner Analog Flame <HMI>
I/O Detection Display
28FD Logic
UV Scanner TBAI
VAIC
28FD
UV Scanner

Turbine
Control
Logic

NOTE: Excitation for the sensors and signal processing is

performed by SPEEDTRONIC Mk VI circuits

Figure 31 SPEEDTRONIC Mk VI Flame Detection ido115

Vibration Protection ceeded, the vibration protection system trips the tur-
bine and annunciates to indicate the cause of the trip.
The vibration protection system of a gas turbine unit Each channel includes one vibration pickup (veloc-
is composed of several independent vibration chan- ity type) and a SPEEDTRONIC Mark VI amplifier
nels. Each channel detects excessive vibration by circuit. The vibration detectors generate a relatively
means of a seismic pickup mounted on a bearing low voltage by the relative motion of a permanent
housing or similar location of the gas turbine and the magnet suspended in a coil and therefore no excita-
driven load. If a predetermined vibration level is ex- tion is necessary. A twisted–pair shielded cable is
FUNDAMENTALS OF SPEEDTRONIC 30 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

used to connect the detector to the analog input/out- Combustion Monitoring

put module.
The pickup signal from the analog I/O module is in- The primary function of the combustion monitor is
putted to the computer software where it is to reduce the likelihood of extensive damage to the
compared with the alarm and trip levels pro- gas turbine if the combustion system deteriorates.
grammed as Control Constants. See Figure 32. The monitor does this by examining the exhaust
When the vibration amplitude reaches the pro- temperature thermocouples and compressor dis-
grammed trip set point, the channel will trigger a trip charge temperature thermocouples. From changes
signal, the circuit will latch, and a “HIGH VIBRA- that may occur in the pattern of the thermocouple
TION TRIP” message will be displayed. Removal readings, warning and protective signals are gener-
of the latched trip condition can be accomplished ated by the combustion monitor software to alarm
only by depressing the master reset button and/or trip the gas turbine.
(L86MR1) when vibration is not excessive. This means of detecting abnormalities in the com-
<RST> bustion system is effective only when there is in-
L39TEST
complete mixing as the gases pass through the
39V
turbine; an uneven turbine inlet pattern will cause an
FAULT
OR
L39VF
uneven exhaust pattern. The uneven inlet pattern
A
A<B
VF could be caused by loss of fuel or flame in a combus-
FAULT B tor, a rupture in a transition piece, or some other
combustion malfunction.
A
VA ALARM
A>B
ALARM B
L39VA The usefulness and reliability of the combustion
monitor depends on the condition of the exhaust
SET TRIP
TRIP
A
A>B
VT AND
L39VT AND thermocouples. It is important that each of the ther-
LATCH
TRIP B
RESET
mocouples is in good working condition.

AUTO OR MANUAL RESET Combustion Monitoring Software

L86AMR

id0057
The controllers contain a series of programs written
Figure 32 Vibration Protection to perform the monitoring tasks (See Combustion
When the “VIBRATION TRANSDUCER FAULT” Monitoring Schematic Figure 33). The main moni-
message is displayed and machine operation is not tor program is written to analyze the thermocouple
interrupted, either an open or shorted condition may readings and make appropriate decisions. Several
be the cause. This message indicates that mainte- different algorithms have been developed for this
nance or replacement action is required. With the depending on the turbine model series and the type
<HMI> display, it is possible to monitor vibration of thermocouples used. The significant program
levels of each channel while the turbine is running constants used with each algorithm are specified in
without interrupting operation. the Control Specification for each unit.

Fund_Mk_VI 31 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
 GE Power Systems

<RST>

COMBUSTION MONITOR ALGORITHM

CTDA

MAX TTKSPL1 MEDIAN

SELECT

MIN TTKSPL2 CALCULATE

ALLOWABLE MEDIAN TTXSPL
SPREAD SELECT
TTXM

MAX TTKSPL5

MIN TTKSPL7

CONSTANTS

A L60SP1
A>B
TTXD2 B

CALCULATE A L60SP2
ACTUAL A>B
SPREADS B

A L60SP3
A<B
B

A L60SP4
A<B
B

id0049

Figure 33 Combustion Monitoring Function Algorithm (Schematic)

The most advanced algorithm, which is standard for a. SPREAD #1 (S1): The difference between the
gas turbines with redundant sensors, makes use of highest and the lowest thermocouple reading
the temperature spread and adjacency tests to differ- b. SPREAD #2 (S2): The difference between the
entiate between actual combustion problems and highest and the 2nd lowest thermocouple
thermocouple failures. The behavior is summarized reading
by the Venn diagram (Figure 34) where:
c. SPREAD #3 (S3): The difference between the
highest and the 3rd lowest thermocouple
reading
VENN DIAGRAM ALSO TRIP IF:
S2 S1
The allowable spread will be between the limits
S
allow S
allow
uK
1 TTKSPL7 and TTKSPL6, usually 17° C 〈30° F) and
53° C (125° F). The values of the combustion moni-
TRIP IF S1 & S2
OR S2 & S3 COMMUNICATIONS
ARE ADJACENT FAILURE

TYPICAL K1 = 1.0
K2 = 5.0
tor program constants are listed in the Control Speci-
TRIP IF S1 & S2

K3
ARE ADJACENT
K3 = 0.8
fications.
MONITOR TC ALARM
ALARM S1 The various controller processor outputs to the
K1 K2 S
allow
id0050
<HMI> cause alarm message displays as well as ap-
Figure 34 Exhaust Temperature Spread Limits
propriate control action. The combustion monitor
outputs are:
Sallow is the “Allowable Spread”, based on aver- Exhaust Thermocouple Trouble Alarm
age exhaust temperature and compressor dis- (L30SPTA)
charge temperature.
If any thermocouple value causes the largest spread
S1, S2 and S3 are defined as follows: to exceed a constant (usually 5 times the allowable
FUNDAMENTALS OF SPEEDTRONIC 32 Fund_Mk_VI
MARK VI CONTROL SYSTEM
 GE Power Systems

spread), a thermocouple alarm (L30SPTA) is pro- If any of the trip conditions exist for 9 seconds, the
duced. If this condition persists for four seconds, the trip will latch and “HIGH EXHAUST TEMPERA-
alarm message “EXHAUST THERMOCOUPLE TURE SPREAD TRIP” message will be displayed.
TROUBLE” will be displayed and will remain on The turbine will be tripped through the master pro-
until acknowledged and reset. This usually indicates tective circuit. The alarm and trip signals will be dis-
a failed thermocouple, i.e., open circuit. played until they are acknowledged and reset.

Combustion Trouble Alarm (L30SPA)

Monitor Enable (L83SPM)
A combustion alarm can occur if a thermocouple
value causes the largest spread to exceed a constant The protective function of the monitor is enabled
(usually the allowable spread). If this condition per- when the turbine is above 14HS and a shutdown sig-
sists for three seconds, the alarm message “COM- nal has not been given. The purpose of the “enable”
BUSTION TROUBLE” will be displayed and will signal (L83SPM) is to prevent false action during
remain on until it is acknowledged and reset. normal start–up and shutdown transient conditions.
When the monitor is not enabled, no new protective
High Exhaust Temperature Spread Trip actions are taken. The combustion monitor will also
(L30SPT) be disabled during a high rate of change of FSR. This
prevents false alarms and trips during large fuel and
A high exhaust temperature spread trip can occur if:
load transients.
“COMBUSTION TROUBLE” alarm exists, the
second largest spread exceeds a constant (usual- The two main sources of alarm and trip signals being
ly 0.8 times the allowable spread), and the low- generated by the combustion monitor are failed ther-
est and second lowest outputs are from adjacent mocouples and combustion system problems. Other
thermocouples causes include poor fuel distribution due to plugged
or worn fuel nozzles and combustor flameout due,
“EXHAUST THERMOCOUPLE TROUBLE”
for instance, to water injection.
alarm exists, the second largest spread exceeds a
constant (usually 0.8 times the allowable The tests for combustion alarm and trip action have
spread), and the second and third lowest outputs been designed to minimize false actions due to failed
are from adjacent thermocouples thermocouples. Should a controller fail, the thermo-
the third largest spread exceeds a constant (usu- couples from the failed controller will be ignored
ally the allowable spread) for a period of five (similar to temperature control) so as not to give a
minutes false trip.

Fund_Mk_VI 33 FUNDAMENTALS OF SPEEDTRONIC

MARK VI CONTROL SYSTEM
GE Power Systems Training

General Electric Company

One River Road
Schenectady, NY 12345
 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Introduction
Our power industry is evolving. Combined cycle units once base loaded are emerging as cyclic or even peaking
generation assets. Dispatch demands we start and load faster, adjust load multiple times within the hour, we
must survive rapid frequency or load transients and adhere to strict environmental regulations. We must
accomplish all efficiently within a fluctuating market.

As our challenges change the state of our hardware and control system have remained the same. The need for
operational flexibility is vital.

GE programs addressing industry needs and definition of terms

x OpFlex is a suite of solutions addressing today’s demands for Operational Flexibility. Ready,
Advantage, Balance & Reserve are collections of applications making up the suite, each addressing
specific customer needs.
x Enhanced Transient Stability (ETS) is one 40+ applications within the OpFlex suite, it is an application of
Balance. ETS addresses rapid grid frequency and load transients by making real-time adjustments in
combustor operation. ETS accomplishes this by leveraging model based control (MBC) technology.
x Model Based Control (MBC) is an advanced technology that improves control accuracy,
responsiveness, reliability and capability. MBC is also known as Direct Boundary Control.
x All Load Cycle Control (ALCC) applies MBC methodology from full-speed no load to peak load. Prior to
the development of ALCC MBC was limited to loads corresponding to Dry Low NOx (DLN) Mode 6 and
higher. Many OpFlex applications utilize MBC. ALCC is the F class control architecture for all future
product development. Many future software and hardware upgrades will require its application.

This document addresses ETS from the operators perspective.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Past, Migrating and Advanced Control Methodologies

Past and Migrating Controls (Mark V and early versions of MkVI)

Traditional control systems utilized ‘scheduled’ based design. These schedules established a control curve using
arrays of control constants. Control constants typically do not change unless manually tuned. These schedules
were based on off-line analysis of lab/field data, worst case scenarios and conservative. Schedules inherently
couple together effectors as Total Fuel, IGV’s, IBH and Fuel Splits.

Schedules that are not adaptive and effectors that are ‘coupled’ limit the controls system’s ability to respond to
rapid grid frequency or load transients, variation in ambient condition, fuel quality, and component
degradation.

Example Schedules

Exhaust Temperature Reference coupled to all effectors

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Migrating and Advanced Controls (Mark Ve, Mark VI (upgraded), MarkVIe)

Today’s rapid grid frequency or load transients, variation in ambient condition, fuel quality, and component
degradation place high demands on our industrial gas turbines. But there are other turbines that operate
under transients far more severe – aircraft engines.

GE Aircraft employs MBC, a controls technology that was designed for flexibility and optimum performance at
any condition. *MBC is a generic term for a type of control methodology, and not a GE product. The core controls
software of ETS has been re-written using MBC.

MBC is also known as Direct Boundary Control where a ‘boundary’ is an operational or design limit (TTXM,
emissions or an equipment design specification). It creates a control loop specific to each to regulate. This
ensures that the turbine, as well as the individual components, is always operating within the intended design
space. It reduces the ‘conservative’ boundary of scheduled based control and removes the inherent coupling of
effectors as each are operated independently.

MBC approaching Boundary MBC within Design Space

MBC Effector Independence

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Past, Migrating and Advanced Control Comparison

ETS Ovrvw for Ops www.geenergytechnicaltraining.com Page 4 of 32

 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Basic MBC Structure

x Critical input variables from the physical gas turbine are read into Input Signal Processing (ISP). ISP is a
fault detection, isolation, and accommodation (FDIA) strategy critical to the accuracy of Adaptive Real-
time Engine Simulation (ARES). ISP will be cover in greater detail later.
x ARES is a high-fidelity model of the gas turbine tuned in real-time to match the performance of the
actual machine at any given moment. ARES calculates the un-measurable cycle parameters that can
be used directly in control loops or as inputs to additional downstream sub-system models. Currently it
is designed for use only when connected to the grid at operating points above FSNL.

x The Adaptive Boundary Model defines the operational boundary conditions at any point in time. To
enhance system performance, the control system must be able to run as close to these boundaries as
possible, regardless of ambient condition, load, fuel properties, or component deterioration.
x The difference between Boundary Targets and Boundary Levels is error, this error prioritized at the
Boundary Control Mode then passed on to Effectors that reduce Boundary error.

Basic MBC Structure

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

ETS Operational Considerations

Everyday operation with ETS remains the same but due to ETS’s enhanced abilities there requires an
understanding of certain operating principles and practices.

• Input Signal Processing (ISP)

o Sensor Displays and specific details
o ISP Fault Detection
o Protective Actions
• MBC Sensor Noise Training
o MBC Sensor Noise Training Procedure
• MBC Sensor Tuning
o MBC Sensor Model Tuning Procedure
• New Start Permissives
• New Runbacks
• New Step to Spinning Reserve
• New Shutdowns
• New Trips
• New Status Fields
• TTRF1 to CA_CRT
• CRT Specifics
• Exhaust isotherm rise
• Base Load Wind Up FSRN
• SSRV P2 Press Control
• Droop Response
• Online Downloads
• Alarms and Unit Response
• Sensor Fault Root Causes and Recommended Actions
• Glossary of Terms

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Input Signal Processing (ISP)

As MBC approaches operational or design limits accuracy becomes critical. The core of MBC is ARES, the
accuracy of ARES is directly dependent upon sensor accuracy. It is therefore more important that sensors be
kept operational and in good calibration for MBC than for a non-MBC control.

Input Signal Processing (ISP) program provides fault detection, isolation, accommodation (FDIA) and initiation of
appropriate control system actions based on input sensor status.

All sensors displayed on the HMI Sensor Data screen below are within the scope of the ISP.

Please note screen location Monitor > Sensor Data.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

ISP Sensor Displays and specific details

Clicking any sensor faceplates will display sensor specific details. There are three possible popup screens that
may display, depending on the redundancy of the sensor set.

Raw Sensor Values – Is each sensor’s current reading in analog and bar chart form.

Output Selection – Is the selected value of ISP to be used for control.

Selection Status – Is the input parameter being examined and how the output selection is being calculated.
Selection status options are:
Median
Weighted average of A & B
Weighted average of A & C
Weighted average of B & C
Channel A
Channel B
Channel C
Model
Default Value

Confidence – Displays on a scale of 0-1 how confident ISP is of that sensor’s reading. Zero indicates a failure
while one indicates a healthy sensor. This box turns red if a failure has occurred.

Long-term (LT) Confidence – Displays on a scale of 0-1 how confident ISP has been in that sensor’s reading
over a period of approximately 24 hours with greater emphasis on more recent sensor behavior. This box turns
red if long-term confidence is very low.

Fault Status – The calculated failure mode. It also identifies when sensors have high spread. This box turns red
if a fault has been detected, yellow if a high spread is detected.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

ISP Fault Detection

All ISP sensors have a faceplate that turns red if any problems are detected.

Fault detection is based on confidence calculations. Specific confidences are combined to determine overall
channel confidences and classification of faults. Instantaneous confidences are combined with recent
historical health information to derive a final confidence value. Lastly, the accommodation takes into account
all system information to decide how to combine each of the sensor readings to obtain a final output value for
the measured parameter, which is used by downstream control functions.

ISP Fault Detection States

No fault
Availability fault

Spike fault

Shift fault

Stuck fault (low noise)

Noise fault (high noise)

Disagreement fault (able to be isolated to a specific channel)

Drift fault

Redundant channel differential (not able to be isolated to a specific channel)

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

ISP Protective Actions

Sensor failures are combined from all monitored sensors. Based upon a pre-determined protective matrix, ISP
takes the appropriate actions to protect the gas turbine.

ISP provides protective flexibility of failed sensors. When certain sensors fail, the unit may still operate at a
reduced output level rather than causing the unit to trip.

Protective Actions
Start inhibit (a start permissive)
Use a model in place of a failed sensor set
Slew out of ETS (step to spinning reserve)
Slew out of AutoTune
Disable liquid fuel water injection
Fail the inlet bleed heat (IBH) system open
Disable the IBH DLN turndown schedule (raise the minimum IGV angle)
Load reject to full speed no load (FSNL)
Fired shutdown
Trip
Fail degraded operation

Fail degraded is an operational mode used when the impact of sensor failures on key gas turbine boundaries
has been quantified, and thus can be conservatively accommodated within parameter boundaries.

The concept is to maintain power generation, while potentially avoiding a shutdown or trip. The magnitude of
potential gas turbine derate is indicated by the fail degraded level, on a scale of 1-10, with higher numbers
being more severe. The scale is relative and does not indicate a specific impact to the gas turbine, as this can
vary with operating condition.

In this example CTIM has failed as determined by the

red faceplate. ISP has taken the protective action of
Fail Degraded Mode Level 9.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
MBC Sensor Noise Training
Noise is unwanted or random data within the sensors signal. ISP looks for abnormally high or low noise relative
to a normal baseline. The baseline is established once during the commissioning of ETS software, during which
adjustments to the default sensor noise levels are made.

Sensor training must be completed before loading the unit beyond spinning reserve for the first time or the unit
will not be allowed to enter cycle control. Sensor training is accomplished at spinning reserve (+/- 10 mw) with
the unit stabilized. If the unit is initially started on liquid fuel, sensor training must also be performed on the first
gas fuel start.

Sensors requiring training are shown on the following HMI screen. The water flow sensors (WQ) must be trained
with water on at higher loads (while on liquid fuel) and critical sensors for the cooling optimization package
(COP) must be trained with the ejector system on in gas fuel emissions compliance mode. Failure to train these
sensors merely results in an alarm, and does not initiate a load lockout.

Fuel Sensor Set

Gas or liquid AFPAP*, AFPIP*, CPD, CTD, CTIM, DWATT, ITDP, CPBH1,
CPBH2*, CPBHDP*, TS2P*, TS3P*, TS3QP9*, TS2QP13*,
W9L*, W9R*, W13L*, W13R*
Gas only FPG2, FTG, FQG, FPGN1*, FPGN2*, FPGN3*, FPGN4*
Liquid only WQ*

*If applicable, dependent on unit hardware and software configuration. Your MBC Sensor Data screen will show
which sensors have enhanced sensor protection, which requires the sensor training.

If failed sensors are not replaced in kind, training should be manually initiated to avoid unnecessary protective
actions.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

Sensor Training (On) Button – This button performs training on all sensor sets that are Enabled and Permitted.
This On button changes to blue (ON) for the duration of the approximate 30 second training process.

Individual Sensor Set Training Status’

Trained/Not Trained - Upon successful completion of sensor training the sensor displays Trained in
green. Otherwise, Not Trained displays in red.

Permitted/Not Permitted - A sensor may only be trained if the unit is placed at the correct load range,
burning the appropriate fuel type, and is at steady state conditions. This is indicated by Permitted
displaying in green. If the sensors permissives for training are not met, Not Permitted displays in red.

Enabled/Disabled - All sensor sets are initially set to enable (Enable button displays in blue) for
convenience. Successful training automatically sets the Disable button (displays in blue), but the user
can enable noise training at a later time by manually selecting the Enable button again.

In the example above:

x CTIM is the only sensor successfully trained
x If the Sensor Training (On) Button were selected
o Only those sensors that are Permitted and Enabled would be trained
o None of the sensors would be trained in the left column as they are all Disabled

If a particular sensor is not successful after the first attempt repeat training for that particular sensor.
If a particular sensor is not permitted check it’s Sensor Displays Fault Status for a possible fault.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
MBC Sensor Noise Training Permissives Per Sensor
Conditions Sensor Set
1. Within 10 MW of spinning reserve AFPAP*, AFPIP*, CPD, CTD, CTIM, DWATT, ITDP, CPBH1,
2. Gas or liquid fuel CPBH2*, CPBHDP*, TS2P* (9FB only), TS3P*, TS3QP9*,
TS2QP13*, W9L*, W9R*, W13L*, W13R*
1. Within 10 MW of spinning reserve FPG2, FTG, FQG, FPGN1*, FPGN2*, FPGN3*, FPGN4*
2. Total gas fuel
Liquid fuel water injection on & flow stable WQ*
Gas fuel emissions compliance mode (6 or 6.3) TS2P* (7FA, 9FA only), TS3QP9*, TS2QP13*

*If applicable, dependent on unit hardware and software configuration. The MBC Sensor Data screen will show
which sensors have enhanced sensor protection, which requires the sensor training.

MBC Sensor Noise Training Procedure

1. Place the unit at the necessary load for the sensor(s) to be trained and allow the unit to stabilize.
2. Navigate to the MBC Sensor Training HMI screen. When the unit has sufficiently stabilized, the
Permissive to train status box for the appropriate sensors will turn from red Not Permitted to green
Permitted.
3. Check that the Enable button is selected for the sensor(s) to be trained, and if not, select it. When a
sensor is ready to be trained, the Enable button will indicate blue and the permissive to train status box
will be green and read Permitted.
4. Ensure that no faults have been indicated on the MBC Sensor Data screen for the sensor(s) to be
trained.
5. Select the sensor training initiation "On" button on the screen to tune the noise settings for the
sensor(s) to be trained. A popup will appear asking to confirm your selection.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
MBC Sensor Tuning
In the event a sensor set fails its sensor model is used to support the unit in fail degraded operation. For
simplicity, sensor models are referred to with an M suffix added to the signal name. CTIM is a compressor inlet
temperature sensor set (hardware) CTIMM is its modeled counterpart.

Sensors are tuned to maximize model accuracy. The tuning process makes permanent adjustments to the
sensor model calculations at the time tuning is initiated. Sensor models should be tuned during commissioning,
after any hardware changes are made or as needed to improve sensor model accuracy or compensate for
changes to system while operating (i.e. input transmitter drift, fouling, etc.).

Value White background - Sensor model output. If the control logic detects a problem displays “Invalid” (see
ITDP and CQBH).

Value Grey background – Hardware output. When a fault is detected text color changes from black to white
(see CPD). This designates that the hardware is not performing optimally but is still being used by the controller.

Faceplate Grey – Controller is using the information provided by the hardware

Faceplate Red - If all available hardware has failed, the unit operates in a fail-degraded state using the output
from the sensor model (see CTIM).

Fail Degraded Box – Becomes visible if a sensor model input is being used and indicates its level of severity.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
Not Tuned - A sensor model has never been tuned

Commisioned – Tuning process has been completed

Permitted - All required permissives for that sensor model

have been met

Not Permitted – Required permissives have not been met

Enable/Enable – If selected and Permitted will initiate the

tuning process. During the tuning process Enable will turn
blue

Permissives
1. Fault Detection Isolation & Accommodation (FDIA) enabled on respective field device(s)
2. Unit not in a transient
3. Applicable sensors Noise trained
4. Breaker closed
5. At least one field device available from ISP

Sensor Model Specific Conditions

Compressor Inlet Temp, Inlet Bleed Heat Flow Gas Fuel Flow Water Flow
CTIMM CQBHM FQGM WQM
Lagged field device CTIM +/-3 none but note 2 pressure inputs 1. On gas not on liquid fuel 1. On liquid fuel
degrees F of current from field devices used 2. Ho or Lo state command 2. Water Flow Stable
3. AutoTune or CDP package 3. Water Stop Valve Open
included

MBC Sensor Model Tuning Procedure

1. Navigate to the MBC Sensor Tuning HMI screen.
2. Assure Permissives and Conditions are met Permitted.
3. Select Enable

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
New Start Permissive
L3SENS_F Sensor Faults - Inhibit Start will be generated if there are 2 or more the following sensor faults.

Sensor Faults
Pointname Description Remaining Note
LFPG2_1_F FPG2 P2 Pressure 1 When Gas Fuel Selected
LFTG_1_F FTG Fuel Temp 1 When Gas Fuel Selected
LFQG_0_F FQG Fuel Flow 0
LAFPAP_1_F AFPAP Atm Press 1
LCPD_1_F CPD Comp Disch Press 1
LCTD_1_F CTD Comp Disch Temp 1
LCTIM_1_F CTIM Comp Inlet Temp 1
LITDP_0_F ITDP Dew Point 0
LCPBH1_0_F CPBH1 IBH CV Upstream Press 0
LCPBH2_0_F CPBH2 IBH CV Upstream Press 0

Sensor faults can be seen on the Monitor > Sensor Data HMI screen

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
New Runback
L70LMBC, MBC Runback
¾ MBC Runback will be true/initiated from any of the following four conditions (in loaded operation)

1. L70LSUC, Load Lock in Startup Control

¾ True if any of the below are true while we are NOT in Cycle Control.
x Machine commanded to a load above 30MW
x CRT exceeds startup control limit of 79.11
x IGV’s are greater than Min

2. IGV L70LQUAT, DLN High Spread runback (Quat Disable)

¾ True if you have a spread 1 & spread 2 high, then the unit will be unloaded till the Quat is
disabled

3. LCA_SENSTRN, ISP Training Logical

¾ The unit can go only up to 30MW Max without the sensor training permissive being met. If
there are any untrained sensors then the machine will be locked out at 30MW. Sensor training
should be done for the machine to enter into Cycle control. Note: Sensor training must be
completed at a load within +/-10MW of spinning reserve.

4. LCY_TPMF_H, Combustion Dynamics High (AutoTune or CDP products ONLY)

¾ Triggered if the combustor experiences sustained high dynamics (median can)

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
New Step to Spinning Reserve
L83ALCC_F, ARES Fault – step to spinning reserve
x True if the machine is on cycle control in loaded operation and you lose the cycle control
permissive (L83CMBC).

Cycle Control will be lost when any of the following occur:

x L83CA_F, ARES diagnostic MBC Fault

¾ True if any of the ARES tuning knobs are at limit (LCA_RKNOB_F=1) or if either of 2 ARES
diagnostic faults are triggered

x L83CBLIMIT, CBV failed to close – load limiting

x LCA_CSENS_F, Sensor Faults - ARES Disabled

¾ True if any of the following are true
ƒ LCTD_0_F, CTD Sensor Failure – 0 Remaining AND LCA_CTDM=0 CTD Sensor Model is not Invalid
OR
ƒ LCTIM_0_F, CTIM Sensor Failure – 0 Remaining AND LCA_CTIMM, CTIM Sensor Model is not Invalid
OR
ƒ 2 or more of the following sensor failures
o LAFPAP_1_F AFPAP Sensor Failure – 1 Remaining
o LCPD_1_F CPD Sensor Failure – 1 Remaining
o LCTD_1_F CTD Sensor Failure – 1 Remaining
o LCTIM_1_F CTIM Sensor Failure – 1 Remaining
o LFPG2_1_F FPG2 Sensor Failure – 1 Remaining (When Running on Gas Fuel)
o LFTG_1_F FTG Sensor Failure – 1 Remaining (When Running on Gas Fuel)
o LDWATT_1_F DWATT Sensor Failure – 1 Remaining
o LITDP_0_F ITDP Sensor Failure – 0 Remaining
o LCPBH1_0_F CPBH1 Sensor Failure – 0 Remaining
o LCPBH2_0_F CPBH2 Sensor Failure – 0 Remaining
o LFQG_0_F FQG Sensor Failure – 0 Remaining (When Running on Gas Fuel)
o LWQ_1_F WQ Sensor Failure – 1 Remaining (When Running on Liquid Fuel)

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
New Shutdown
L94SENS, Sensor Faults – Shutdown Unit
¾ True if;

Any of these Sensor Faults occur before the breaker is closed

L3SENS_F Sensor Faults - Inhibit Start (see New Start Permissive)
LFPG2_1_F, FPG2 Sensor Failure – 1 Remaining (When Running on Gas Fuel)
LCPD_1_F, CPD Sensor Failure – 1 Remaining
LCTIM_1_F, CTIM Sensor Failure – 1 Remaining
OR
LFTG_0_F FTG (Gas Temp) Sensor Failure – 0 Remaining while unit is running on gas

New Trip

L86SENS, Sensor Faults – Trip Unit

¾ True if;

The unit is running in loaded operation and you have 0 CPD sensors available and the CPD
Sensor Model is invalid.
OR
The unit is running on Gas and has 0 FPG2 sensors available

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
New Status Fields

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
TTRF1 to CA_CRT
Combustion Reference (CRT) is used to define combustion mode transfer points (including staying in emissions
compliance) and fuel split schedules for the DLN system, replacing the functionality of the traditional TTRF1
signal. CRT can also be used as a boundary for control of specific gas turbine cycle effectors as required
by given engine configuration. Depending on the plant requirements, CRT can also be used for scheduling the
operation of additional plant equipment through the distributed control system (DCS).

Many cycle parameters, including the CRT, are encoded; the value is not given in engineering units but rather in
non-dimensional units. The encoded values still allow for full evaluation and manipulation of gas turbine
operation.

CRT Specifics (7FA DLN2.6 units)

Units without OpFlex Startup Nox Units with OpFlex Startup Nox

The default values will be in the code prior to DLN tuning. The final values can be added to this chart once the
post-tuning report is provided.

Exhaust Isotherm Rise

Exhaust isotherm value will rise by approximately 15 Deg F for 7FA units. ETS uses a higher fidelity exhaust
temperature correction model then was available in the past. The intent of this model change and resultant
isotherm change is to accurately represent the bulk exhaust temperature. There will be no change to the HRSG
inlet temperature or to DLN turndown.

Base Load Wind Up FSRN

Base load FSRN windup will be overridden when the unit is commanded off of base load. This means that the
windup delay for moving the unit off of base load is now eliminated.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
SSRV P2 Press Control
SSRV P2 fuel pressure control loop is now gain scheduled. For MKVIe units this regulator will change from a
pressure control regulator to a position control regulator. The P2 pressure control loop is now coded in
application code for both the MKVI and MKVIe applications.

Droop Response
Droop response will sustain at part load operation. Previously our part load governor would override the droop
response of the unit. With ETS the droop response will be sustained as long as the system remains off nominal
frequency.

Default droop dead band is set to 0.02% speed. This can be changed on a site specific basis. This is typically a
grid operator specification

Online Downloads
GEs default position on customer or 3rd party software is to disable it from our core design but leave it in place.
It is then up to the customer to re-attach or re-engineer their custom software as they see fit. If GE replaces an
entire software module we will not re-insert non GE software back into this module, so in this instance the
customer software may not be in place when the files are returned.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
Alarms and Unit Response
Recommended Operator
Alarm Signal Fault Condition Controller Display / Action Actions
L83CA_F_A • ARES Model Fails ARES DIAGNOSTIC FAULT - MBC Allow at least five minutes for the
DISABLED alarm to clear. This fault requires a
master reset to clear. If the alarm
Step the unit to spinning reserve. becomes active again (or if the
original alarm never clears), contact
the PAC center for assistance.

L30SUC_LLO • In startup control at too high of Start Up Control Load Lock Out • ARES model has failed
a load, CRT, or not on minimum Alarm (see L83CA_F_A)
IGV angle.
• Ensure compressor bleed
• Unable to enter cycle valves are closed.
control.
• Sensor failures have disabled
the ARES model. See
LCA_CSENS_A
for details on specific
combinations of sensor
failures).

• All CPD sensors unavailable

AND CPD sensor model not
valid

• All CTD sensors unavailable

AND CTD sensor model not
valid

• All DWATT sensors unavailable

AND DWATT sensor model not
valid

L30TS2PSENS_A • Ejector system not SENSOR FAULTS - DISABLE EJECTOR Inspect Ejector sensors.
operational SYSTEM Refer to Sensor Fault Root Causes and
Recommended Actions

L30TSQPSENS_A • Ejector system not SENSOR FAULTS - DISABLE EJECTOR Inspect Ejector sensors.
operational ISOLATION VALVE

LCA_SENSTRN_A • Sensor training has not been MBC RUNBACK DUE TO Perform sensor training
performed or was not successful INADEQUATE SENSOR TRAINING

LTS2P_TRNP_A • Sensor training for TS2P has not TS2P SENSOR HAS NOT BEEN Perform sensor training
been performed or was not TRAINED - PERFORM SENSOR
successful TRAINING PROCEDURE

LTS2QP13_TRNP_A • Sensor training for TS2QP13 TS2QP13 SENSOR HAS NOT Perform sensor training
has not been performed or BEEN TRAINED
was not successful

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

LTS3QP9_TRNP_A • Sensor training for TS2QP9 TS3QP9 SENSOR HAS NOT Perform sensor training
has not been performed or BEEN TRAINED
was not successful

LWQ_TRNP_A • Sensor training for WQ has not WQ SENSOR HAS NOT BEEN Perform sensor training
been performed or was not TRAINED - PERFORM SENSOR
successful TRAINING PROCEDURE

L3SENS_A • One or less CPD sensors SENSOR FAULTS - INHIBIT START Examine sensor faults and sensor
available OR model validity changes (with
• One or less FPG2 sensors Start Inhibited associated alarms) that caused
available OR protective action. Refer to Sensor
Fault Root Causes and Recommended
• One or less CTIM sensors
Actions
available OR

• Two or more of the

following are true:

í One or less AFPAP

sensors available
í One or less CPD
sensors available
í One or less CTD
sensors available
í Zero ITDP sensors
available
í Zero CPBH1 sensors
available
í Zero CPBH2 sensors
availableí
One or less
FPG2 sensors
available
AND not on total liquid fuel
í One or less FTG
sensors available
AND not on total liquid fuel
í Zero FQG sensors
available AND not on
total liquid fuel
í Zero FQLM1 sensors
available AND on total
liquid fuel

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

L30LRSENS_A • Generator breaker closed AND SENSOR FAULTS – LOAD REJECT Examine sensor faults and sensor
all DWATT sensors unavailable TO FSNL model validity changes (with
AND DWATT sensor model not associated alarms) that caused
valid
Load Reject to FSNL protective action. Refer to Sensor
Fault Root Causes and Recommended
Actions
L86SENS_A • All FPG2 sensors SENSOR FAULTS – TRIP UNIT Trip Examine sensor faults and sensor
unavailable AND on total model validity changes (with
gas fuel OR associated alarms) that caused
• All CPD sensors unavailable protective action. Refer to Sensor
AND CPD sensor model not Fault Root Causes and Recommended
valid AND at minimum Actions
operating speed AND
generator breaker closed

L94SENS_A • All FTG sensors SENSOR FAULTS – Examine sensor faults and sensor
unavailable AND on total SHUTDOWN UNIT model validity changes (with
gas fuel OR associated alarms) that caused
• Start permissive conditions not Fired Shutdown Initiated protective action. Refer to Sensor
met AND breaker not closed Fault Root Causes and Recommended
AND not tripped AND not Actions
already shutting down

L3BHSENS_A • All CTIM sensors unavailable SENSOR FAULTS - FAIL BLEED Examine sensor faults and sensor
AND CTIM sensor model not HEAT OPEN model validity changes (with
valid OR associated alarms) that caused
• All AFPAP sensors IBH System Failed Open (by protective action. Refer to Sensor
unavailable solenoid) Fault Root Causes and Recommended
Actions

L3BHTSENS_A • CPBH2 sensor not available SENSOR FAULTS–DISABLE IBH DLN Examine sensor faults and sensor
AND CQBH sensor model TURNDOWN model validity changes (with
not valid associated alarms) that caused
IBH DLN Turndown Schedule protective action. Refer to Sensor
Disabled, Minimum IGV Angle Fault Root Causes and Recommended
Increased Actions

L3WQSENS_A • WQ sensor failure of any type SENSOR FAULTS - DISABLE WATER Examine sensor faults and sensor
detected INJECTION model validity changes (with
associated alarms) that caused
Liquid Fuel Water Injection protective action. Refer to Sensor
System Disabled Fault Root Causes and Recommended
Actions

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

L30LRSENS_A • Generator breaker closed AND SENSOR FAULTS - LOAD REJECT Examine sensor faults and sensor
all DWATT sensors unavailable TO FSNL model validity changes (with
AND DWATT sensor model not associated alarms) that caused
valid
Load Reject to FSNL protective action. Refer to Sensor
Fault Root Causes and Recommended
Actions

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
LCA_SENS_FD • A sensor fault in one of the Fail degraded biases applied to Refer to the table Sensor Fault
L30AFPAP_0
L30AFPAP_1 monitored parameters (AFPAP, machine boundary targets as Root Causes and Recommended
L30AFPAP_2 CPD, CTD, CTIM, DWATT, FPG2, appropriate to accommodate Actions
L30AFPAP_DIF FPGN1, FPGN2, FPGN3, FQG,
L30CPBH1_0 these sensor failures.
FQLM1, FTG, ITDP, WQ, TS2P,
L30CPBH2_0
L30CPD_0 TS2QP13, or TS3QP9) has
L30CPD_1 occurred.
L30CPD_2
L30CPD_DIF
L30CTD_0
L30CTD_1
L30CTD_2
L30CTD_DIF
L30CTIM_0
L30CTIM_1
L30CTIM_2
L30CTIM_DIF
L30DWATT_0
L30DWATT_1
L30DWATT_DIF
L30FPG2_0
L30FPG2_1
L30FPG2_2
L30FPG2_DIF
L30FPGN1_0
L30FPGN1_1
L30FPGN1_2
L30FPGN1_DIF
L30FPGN2_0
L30FPGN2_1
L30FPGN2_2
L30FPGN2_DIF
L30FPGN3_0
L30FPGN3_1
L30FPGN3_2
L30FPGN3_DIF
L30FPGN4_0
L30FPGN4_1
L30FPGN4_2
L30FPGN4_DIF
L30FQG_0
L30FTG_0
L30FTG_1
L30FTG_2
L30FTG_DIF
L30ITDP_0
L30ITDP_1
L30ITDP_2
L30ITDP_DIF
L30WQ_0
L30WQ_1
L30WQ_DIF
L30TS2P_0
L30TS2P_1
L30TS2P_2
L30TS2P_DIF
L30TS2QP13_0
L30TS2QP13_1
L30TS2QP13_2
L30TS2QP13_DIF
L30TS3QP9_0
L30TS3QP9_1
L30TS3QP9_2
L30TS3QP9_DIF

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

LCA_ATSENS_A • All FPGN1 sensors SENSOR FAULTS – Examine sensor faults and sensor
unavailable OR AUTOTUNE DISABLED model validity changes (with
• All FPGN2 sensors associated alarms) that caused
unavailable OR Slew Out of Autotune protective action. Refer to Sensor
MBC,FSR-VPR Loop Disabled Fault Root Causes and Recommended
• All FPGN3 sensors
Actions
unavailable
LCA_CSENS_A • All CTD sensors unavailable SENSOR FAULTS – ARES Examine sensor faults and sensor
AND CTD sensor model not valid DISABLED model validity changes (with
OR associated alarms) that caused
• All CTIM sensors unavailable Slew Out of ALCC (Step to protective action. Refer to Sensor
AND CTIM sensor model not Spinning Reserve) Fault Root Causes and Recommended
valid OR Actions
• FQLM1 sensor unavailable AND
on total liquid fuel OR

• 2 or more of the following are

true:

í One or less AFPAP

sensors available
í One or less CPD
sensors available
í One or less CTD
sensors available
í One or less DWATT
sensors available
í Zero ITDP sensors
available
í Zero CPBH1 sensors
available
í Zero CPBH2 sensors
available
í One or less FPG2
sensors available
AND not on total liquid fuel
í One or less FTG
sensors available
AND not on total liquid fuel
í Zero FQG sensors
available AND not on
total liquid fuel
í Zero FQLM1 sensors
available AND on total
liquid fuel
í One or less WQ
sensors available
AND water injection is on

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators

L30CPDM • CPD sensor model is not valid CPD SENSOR MODEL INVALID Check health of input sensors to
model first (CPD, DWATT). Verify
CPD sensor model output is ignored in wiring, calibration, device integrity,
downstream logic, ex. input signal etc. Replace if necessary. Repeat for
processing (ISP). all other ARES analog sensor inputs.

L30CTDM • CTD sensor model is not valid CTD SENSOR MODEL INVALID Check health of input sensors to
CTD sensor model output is ignored in model first (CTD, DWATT). Verify
downstream logic, ex. input signal wiring, calibration, device integrity,
processing (ISP). etc. Replace if necessary. Repeat for
all other ARES analog sensor inputs.

L30DWATTM • DWATT sensor model is not DWATT SENSOR MODEL INVALID Check health of input sensors to
valid DWATT sensor model output is model first (CPD, CTD). Verify wiring,
ignored in downstream logic, ex. input calibration, device integrity, etc.
signal processing (ISP). Replace if necessary. Repeat for all
other ARES analog sensor inputs.

L30CTIMM • CTIM sensor model is not valid CTIM SENSOR MODEL INVALID Check health of input sensors to
CTIM sensor model output is ignored model (CTD, CPBH1, CPBH2). Verify
in downstream logic, ex. input signal wiring, calibration, device integrity,
processing (ISP). etc. Replace if necessary. Turn off
evaporative cooling.

L30FQGM • FQG sensor model is not valid FQG SENSOR MODEL INVALID Check health of input sensors to
FQG sensor model output is ignored in model (CPD, FPG2, FTG, FPGN1,
downstream logic, ex. input signal FPGN2, FPGN3). Verify wiring,
processing (ISP). calibration, device integrity, etc.
Replace if necessary.

L30CQBHM • CQBH sensor model is not valid CQBH SENSOR MODEL INVALID Check health of input sensors to
CQBH sensor model output is ignored model (CTD, CPBH1). Verify wiring,
in downstream logic, ex. input signal calibration, device integrity, etc.
processing (ISP). Replace if necessary.

L30ITDPM • ITDP sensor model is not valid ITDP SENSOR MODEL INVALID Check health of input sensors to
ITDP sensor model output is ignored in model (AFPAP, CTIM). Verify wiring,
downstream logic, ex. input signal calibration, device integrity, etc.
processing (ISP). Replace if necessary.

L30WQM • WQ sensor model is not valid WQ SENSOR MODEL INVALID Check health of input sensors to
WQ sensor model output is ignored in model (WQDP). Verify wiring,
downstream logic, ex. input signal calibration, device integrity, etc.
processing (ISP). Replace if necessary.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
Sensor Fault Root Causes and Recommended Actions
Possible Causes of Sensor Faults Recommended Operator Actions

Control hardware failure • Examine I/O board/pack diagnostics log

• Check proper I/O layout/fanning to ensure single panel loss does not
result in sensor signal loss
• Ensure all controllers in controlling state (not inputs enabled, etc.)
Dirty pneumatic or sensing lines • Find source of contamination and seal
• Clean or replace sensing lines
External interference • Check if new equipment recently installed near sensing lines/wiring
• Install additional electromagnetic shielding
• Ensure proper signal path separation from power wiring
• Re-route sensing lines/wiring
Faulty or broken transmitter • Physically inspect transmitter for damage, wear, and leakage
• Replace transmitter
• Perform signal injection tests to confirm proper operation
Incorrect I/O settings • Double-check device settings including I/O settings in application software
• Check I/O configuration in application software is consistent with panel
l
Loose, broken, and/or incorrect wiring • Ensure tight terminations in control cabinets and connections at the device
• Perform loop checks
Sensor not properly calibrated • Recalibrate the sensor
Sensors isolated or valved out • Remove isolation block (if present)
• Confirm sensors not in calibration mode
• Disengage isolation valve (if present)
Wrong installation • Thermocouples: check proper well installation and insertion depth
• Differential pressures: ensure lines piped to correct sides of transmitters
• Pressure transmitters: look for leakages
• Check sensor placed in proper physical location/tap

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
Glossary of Terms
(ARES) Adaptive Real-time Engine Simulation is a high-fidelity model of the gas turbine that is continuously
tuned in real-time to match the performance of the actual machine.

(ALCC) All Load Cycle Control is a technology that implements MBC direct boundary control from breaker
closure for the bulk fuel/air boundaries.

AutoTune is a software product that adds closed loop DLN split control to ETS, enabling greater allowable MWI
variation and elimination of seasonal retunes.

Boundary is a limit, such as an operational limit or a design limit. An example would be the typical 9 ppm NOx
limitation for a 7FA+e gas turbine.

Boundary Models are physics-based models that capture the fundamental behavior of the operational
boundaries.

(CAF) Coordinated Air-Fuel is a control strategy used to maintain an operable global fuel-air mixture in the
combustor during gas turbine transient events.

(CRT) Combustion Reference is a control system parameter used to schedule combustion mode transfer points
and split schedules.

Effectors are the control elements that alter machine operation; IGV, inlet bleed heat, total fuel flow, fuel
temperature, and DLN fuel splits.

(ETS) Enhanced Transient Stability is a product that utilizes the technology platform of ALCC and provides
improved transient response of GE gas turbines using MBCAF, the GFF, and transient fuel split biasing.

(GFF) Grid Frequency Filter is a speed filter specifically designed for the ETS product utilized to shelter the gas
turbine from the full effects of extreme frequency disturbances.

(CSS Toolbox) GE Control System Solutions is a Windows-based application used to configure Mark* VI control
hardware and software.

Health is a term that defines whether a variable is functioning as expected.

(ISP) Input Signal Processing is a signal-processing-based fault detection, isolation, and accommodation
strategy applied to all sensor inputs critical to the accurate operation of ARES.

(LIC) Loop in Control is a status indication that displays which control loop is generating the output reference
for an effector.

(MBC) Model-based Control is a control strategy designed to improve the performance and operational
flexibility of a GE gas turbine.
(MBCAF) Model-based Coordinated Air-Fuel is a coordinated air-fuel strategy specific to the ETS product that
creates a model of an ideal IGV-to-FSR relationship then uses that modeled relationship to control IGVs in
response to a fast FSR motion.

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 OpFlex
Enhanced Transient Stability (ETS)
Overview for Operators
ToolboxST* application is a Windows-based application used to configure Mark Ve and Mark VIe control
hardware and software.

(TRT) Turbine Reference is a control system parameter used to define proper or nominal turbine operation,
predominantly at base load.

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GE Energy
Human-Machine Interface (HMI)
Product Description
GEI-100485D
This document is distributed for informational purposes only.
It is not to be construed as creating or becoming part of any
General Electric Company contractual or warranty obligation
unless expressly stated in a written sales contract.
” 2008 by General Electric Company, USA. All rights reserved.
Section Page
Introduction ................................................................................................................. 3
Related Documents...................................................................................................... 3
Networking/Distributed Operation .............................................................................. 4
Diagnostic Options........................................................................................ 5
Communications Drivers .............................................................................. 6
Time Synchronization ................................................................................... 6
Screen Description....................................................................................................... 7
Graphics Tools ............................................................................................................ 8
Alarm/Event Management......................................................................................... 10
Alarm/Event Log......................................................................................... 11
Dynamic Data Recorder .............................................................................. 11
Data Historian ............................................................................................. 11
Historical Trip Log...................................................................................... 11
Trending with CIMPLICITY .................................................................................... 12
Trending with Toolbox / ToolboxST .......................................................... 13
Security...................................................................................................................... 13
Hardware Options...................................................................................................... 14

ActiveX, Excel, Microsoft, PowerPoint, Visio, Visual Basic, and Windows are
registered trademarks of Microsoft Corporation.
AutoCAD is a registered trademark of Autodesk, Inc.
ARCNET is a registered trademark of Datapoint Corporation.
CIMPLICITY, and Symbols and OpenObjects are registered trademarks of GE
Fanuc Automation North America, Inc.
Ethernet is a registered trademark of Xerox Corporation.
EX2100 and ToolboxST are trademarks of General Electric Company, USA.
Modbus is a registered trademark of Schneider Automation.
Introduction
GE Energy uses the Human-Machine Interface (HMI) as its primary operator
interface for the control of turbines, generators, compressors, and balance of plant
applications. It typically consists of a Windows® operating system, CIMPLICITY®
graphics user interface Control System, Toolbox or ToolboxST™ maintenance
software, and a variety of application-specific software packages such as Network
Time Protocol (NTP).
The HMI is also available as ™
The HMI is most commonly used for Mark VI, Mark VIe, and EX2100 excitation
an upgrade for installed units systems, which are currently in production. There is little functional difference
including Mark V and between interfaces to Mark VI and Mark VIe controllers since they both
EX2000 control systems. £
communicate on Ethernet networks and have similar maintenance software.
However, there are more differences when applied to Mark V and EX2000. These
systems can co-exist at the same site with Ethernet interface to Mark VI/Mark
£
VIe/EX2100, and with ARCNET interface to Mark V/EX2000, as an example.
HMIs are designed as important but non-essential components in the control and
protection of plant equipment. Vital control loops, sequencing, and trip protection
are located in the controllers and not in the HMI. Similarly, accurate alarm, event,
and Sequence of Events (SOE) data is fundamental to proper operation and
maintenance of the equipment, so this data is time-tagged in the controllers with
high-resolution time-tags and then transmitted to the HMI(s) for display and logging
to ensure optimum process and control diagnostics.
Operators and maintenance personnel interface with the controllers on modern
client/server networks with local and remote stations. Access can be restricted in
multiple levels for each user. Additional security is provided as part of the normal
software engineering process, which validates the various software packages as an
integrated system, and for compliance to international security standards.

Related Documents
The following documents also apply to the HMI.
GEH-6126 Volume I, HMI Operator’s Guide
GEH-6126 Volume II, HMI Application Guide

GEI-100485D Human-Machine Interface (HMI) x 3

Networking/Distributed Operation
GE Energy’s current control systems use 10/100MB Ethernet for communication of
data between the controllers (peer-to-peer), and between the controllers and the
HMI(s). This internal GE network, referred to as the Unit Data Highway (UDH), is
available in redundant configuration. Network rules conform to IEEE 802.3.
Interface to other plant equipment is available through a separate 10/100MB TCP/IP
Ethernet network referred to as the Plant Data Highway (PDH). In general, the
Controls currently in internal UDH is considered a control network that commonly communicates
production use 10/100MB important equipment parameters at frame rate (the speed that the controllers are
Ethernet at all levels. executing the application software). The HMI(s) isolate the UDH from the plant
PDH, which is also available in redundant configuration. Tasks such as file transfers
are made on the PDH.
Plant Data Highway (PDH) - Ethernet

HMI
Operator and
Maintenance Stations

Unit Data Highway (UDH) - Ethernet Peer-to-Peer Communications

Mark VI, Mark VIe, EX2100, LS2100, GE PLCs, Protection Relays

Stage Link - ARCNET

Mark V and EX2000

HMI Networks for Current and Legacy Products

Standard network diagnostics include a message identifying system health. An

optional Network Diagnostics system is available to monitor the entire network
infrastructure, including switches, servers, and GE controllers on the UDH and PDH.
If a problem is detected, various alerts and notifications are issued. This system is
based on Simple Network Management Protocol (SNMP), which is applied in a site-
specific topology.

4 x Human-Machine Interface (HMI) GEI-100485D

 ABC Energy

Network Diagnostics

Diagnostic Options
Network diagnostics contain both messages and animated screen graphics.
Messages include:
x Affected node
x Affected link
x Device affected by lost data
x Time tag
Animated screen graphics include:
x Topology screens
x Switch port status screen(s)
x Shortcut menus

GEI-100485D Human-Machine Interface (HMI) x 5

 Communications Drivers
Operators can issue commands and monitor data through the HMI or through a link
to another system such as a Distributed Control System (DCS). Normally, any
command that can be issued at the HMI through a start/stop command or a numerical
setpoint can also be issued from a linked computer. Similarly, all sequential, analog,
alarm, and event data is available through communication links.
CIMPLICITY supports a wide range of communication drivers, and GE Energy
offers a subset of these drivers with supporting documentation. Each driver varies
according to data format, throughput, and functionality.
Primary Protocols for Communication to Remote Computers

Feature Modbus
£ GSM OPC DNP 3.0

Physical layer Serial/Ethernet Ethernet Ethernet Serial/Ethernet

Client / Server Client/Server Server Client/Server Server
Time tags Yes Yes Yes
Alarm queue and commands Yes Yes
Alarm / Event exception reports Yes Yes
These protocols are available from major controls suppliers. A HMI client-to-
programming interface (PI) server is also available with Ethernet. This server
requires PI and application programming interface (API) node buffering, and
supports 500 points at 1 Hz without local time tags.

Time Synchronization
Inter-Range Instrumentation Group (IRIG-B) is most commonly used for time
synchronization between the HMI and a remote time source, as well as
synchronization between multiple GE controllers on the UDH. Refer to the following
table for levels of synchronization and methods for implementation.
Time Synchronization Options

Synchronization Time Reference HMI Accuracy Coherence

None None Drift Drift
Low resolution HMI CPU clock No server or client 30ms 30 to 200ms
High resolution bc635pci clock or NTP client-tracking ±1ms ±1ms to source
customer reference NTP server
±2ms between units
High resolution Global Positioning bc635pci and NTP ±1ms ±1ms to source
Satellite (GPS) server
GPS receiver ±2ms between units

Note Time accuracy is the difference between the time reported on a local
controller, such as a turbine control, and a time source. Time coherence is the
difference in time between controllers.

6 x Human-Machine Interface (HMI) GEI-100485D

Screen Description
A typical screen (shown below) has a gray background with a title bar at the top, a
screen navigation bar on the right, and an alarm field at the bottom.
The title bar contains the site name, equipment identifier, screen name, time, and
date. In the unlikely event that communication is lost between the HMI and the
controller, the time-date field turns black. Also, animated graphics turn black, data
fields display with ###s, and an alarm message is generated.

Title Block Time & Date Screen Name

z Unit # (Gas Turbine #1)

z Typical System Responses

z Select Control Group

z Select Start-up Screen

z Functional Operator
Commands
z Command Acknowledge
Required for Most
Commands
z Active Status Feedback

z Active Trending

z Diagnostic Reset
z Active Alarm Management

Typical HMI Operator Screen

The navigation bar on the right-hand side of the screen is arranged according to
screen hierarchy (top-to-bottom).
System Overview displays all control equipment, including
x Equipment selection (steam turbine, HRSG)
x Screen categories (Control, Monitor, Auxiliaries, and Tests)
x Specific screens within the screen category currently selected
x Master and Diagnostic resets
The alarm field at the bottom of the screen displays new alarms without changing
screens. Also, any nuisance alarms, such as field grounds, can be locked out, alarm-
specific comments can be added, and alarm filtering is provided. The full alarm
queue is available, if needed.

GEI-100485D Human-Machine Interface (HMI) x 7

 An animated graphic of the process is normally located in the middle of the screen
with relevant message fields and operator selections. Some objects, such as valves,
may have built-in trends related to the particular parameters being controlled by the
valve. Many applications display all primary operator commands and pertinent data
on one screen to minimize navigation. Operator commands such as start/stop
generate a dialog box requesting confirmation. Once the command is sent to the
controller and run, the command button changes color.

Graphics Tools
CimEdit
CimEdit is used to create screen graphics. It enables importing of OLE and Windows
Metafile (wmf) objects, plus ActiveX® objects like trending, SPC charts, and Alarm
Viewers. Third-party OLE and ActiveX objects such as Excel® spreadsheets and
charts, and bitmaps can also be imported.
Flexible, user-friendly tools Toolbars allow you to create and modify screens. Once objects are created, they can
are provided for screen- easily be resized, rotated, or moved. After objects are placed on the screen, they can
building and editing. be aligned automatically with a configurable grid, or in relation to each other.
Double-clicking an object opens its property page. These pages allow quick
navigation and specify animation attributes, including rotation, fill, movement, color
and text annunciation, geometry, scaling, events, procedures, and scripts.
Major features include the following:
Interactive, dynamic configuration is used to add or modify screens or live point
configuration data from anywhere within CimEdit without shutting down the HMI.
Point Browser dialog box provides access to any CIMPLICITY point on the
network for object animation.
Frame Animation is a compound object that defines a series of frames. Each frame
can consist of different objects, and displays based on the value of an expression. As
a result, areas of the screen can change like a slide show.
Metafile Import is used to copy and paste wmf objects produced by programs like
AutoCAD®, Visio®, and PowerPoint® into CimEdit. The imported images can be
decomposed into CIMPLICITY objects. They can also be fully animated, unlike
bitmap imports, which remain single, static objects.
Online Help offers comprehensive, indexed documentation.
Object Help can be configured for any screen object and easily accessed at runtime.
Dynamic Screen Testing is used to test screen changes without changing the
original screen. By using the test button on the standard menu bar, a CimView
window lets you review edits prior to saving them.

Symbols and OpenObjects™ Library

Extensive symbols and objects libraries are provided. With objects, custom objects
can be created and dragged-and-dropped into screens from CIMPLICITY Object
Explorer. Once the objects are dropped, a prompt displays to enter configuration
information. Objects can also be generated that automatically create a complete point
configuration.

8 x Human-Machine Interface (HMI) GEI-100485D

 OpenObjects
OpenObjects simplifies the creation of projects that involve common objects or
repetitive tasks. Point structure definition allows easy grouping of information.
OpenObjects can be linked to graphic objects with associated scripts. Point
configuration can be automated so all points associated with the object are
automatically configured by the system.

Application-specific Objects
GE Energy provides a library of objects tailored to applications of turbines,
generators, compressors, and plant controls. These objects are convenient to use, and
provide consistency of graphic standards throughout the plant and from site to site.

Linked Scripts
Scripts can be linked to objects. If a script is associated with a master object, it is
replicated in all linked objects. Changes made to the script automatically change all
the linked objects, as well.

Object Model
Using OLE automation, the object model offers an external programming interface
for CimEdit and CimView. Any screen can be automatically created and modified
using CimEdit features and enjoy complete control of CimView from either a script
embedded in CimView or from any Visual Basic® application. The object model
reduces the time required to create new systems. If similar screens are needed, a
Visual Basic program can be written to automatically generate them.

CimView
CimView is the graphics runtime portion of CIMPLICITY. Process information
displays in both text and graphic formats. Alarms, dialog boxes, and animation
features enhance ease-of-operation and system maintenance.

GEI-100485D Human-Machine Interface (HMI) x 9

Alarm/Event Management
Alarm View is an ActiveX object embedded in CimView screens. An alarm field is
normally located at the bottom of most screens; the full queue can be observed on a
separate screen, as well.
As previously mentioned, alarms and events are normally time-tagged locally, within
the controllers, and transmitted to the HMI where they are placed in the alarm queue
with the local time tag. These time tags have the resolution of the controller’s frame
If application software is rate for the application software. This is true for alarms (process and diagnostic) and
running at 20 ms to control a events, but SOE is a special category. SOE is intended to identify the source of a trip
turbine, the alarm time tags at the plant level. Therefore, most GE Energy control systems have standard 1ms
will have 20 ms resolution. time tags for all contact inputs. For effectiveness at the plant level, each controller
needs to be synchronized to each other and to other systems in the plant, as
previously discussed.
The alarm queue contains messages for:
x Process alarms (example, high HP-bearing vibration)
x Process events (example, breaker closed)
x SOE (example, changes to the state of contact inputs)
x Diagnostic alarms (example, power supply voltage low)
Filtering allows any combination of these four categories to display on a particular
HMI. They can then be grouped with any combination of alarms/events from specific
equipment in the plant, such as a HRSG or generator.
The alarm field at the bottom of the screen shows the most recent alarm messages
with:
x Date
x Time
x Alarm ID
x Device/equipment number
x Confirmation of whether the alarm has been acknowledged
x Current state of the origin of the alarm
x A text field describing the alarm condition
The alarm summary allows operators to acknowledge and silence new alarms, lock
out nuisance alarms, add comments, and provide filtering. It can be sorted according
to:
x Time
x Tag
x Area
x Priority
x Status

10 x Human-Machine Interface (HMI) GEI-100485D

 Alarm/Event Log
In addition to the alarm summary, alarms and events are logged in memory on the
HMI. Thirty days or 10 MB of storage is provided per unit (equipment) with logging
in chronological order or according to the frequency of occurrence. This is a rolling
log that will overwrite when the queue is full.
The log can be exported through printing in its entirety to a printer on the network,
logged spontaneously as new alarms/events occur on a dot matrix printer, or
extracted as a file (dca or csv).
For products currently in production, the embedded software package that stores
historical data is the Data Historian, which is part of the Toolbox and ToolboxST
maintenance software. Different software tools are used for legacy products, and the
logs reflect differences in the controllers, such as time resolution.

Dynamic Data Recorder

Dynamic data recording Controllers currently in production have a feature called Dynamic Data Recorder,
provides either fast or slow which is part of the Toolbox/ToolboxST software. Capture buffers embedded in the
trending. application software capture data at frame rate. This provides high-resolution time
tags (at frame rate) for a large quantity of data. Resolution can range from frame rate
to frame rate x 1,500. A process variable is used to trigger data recording; data can
be captured with a predetermined number of samples prior to and after the trigger.
Data collection can also be triggered by a comparison between variables. Up to 96
variables can be collected in each capture buffer, and up to 12 capture buffers can be
provided per unit.

Data Historian
The Data Historian in Toolbox and ToolboxST stores short-term historical data
including alarm/event data and high-resolution or low-resolution data from the
Dynamic Data Recorder. Capacity is rated at 200 points collected every eight
seconds for 30 days. Data can be exported through printouts or files in .dca/.csv
format.

Historical Trip Log

Precision trip logs are A historical trip log is provided for all controls of rotating machinery. It uses the
provided on all systems to Dynamic Data Recorder and Data Historian to build an application-specific trip log
minimize mean-time-to-repair for analysis of the key control parameters, alarms (up to 200), events (up to 200),
(MTTR) and SOE data (up to 200) leading up to, and immediately following, the trip event.
Capture buffers in the controller’s application software collect the data at frame rate
for best resolution. The data for the last 30 trips is stored online and available for
export through printouts or files in dca and csv format.
Data Samples
Pre-trip 19 hours at 10-minute intervals
Pre-trip Four hours at one-minute intervals
Pre-trip 40 minutes at 10-second intervals
Pre-trip 19 minutes at one-second intervals
Pre-trip 45 seconds at 200ms intervals
Pre-trip 15 seconds at frame rate
Post-trip 15 seconds at frame rate

GEI-100485D Human-Machine Interface (HMI) x 11

Trending with CIMPLICITY
The trending tools are used to analyze data collected by the CIMPLICITY system or
from other third-party software packages. Current and past trends can be compared
to quickly identify and correct process problems.
Features include:
x Full integration with CimView
x Multiple charts per graphic screen
x Default parameters for easy setup
x Unlimited number of pens per chart
x Configurable colors, fonts, line styles, and legend
x Pens that represent multiple data sources on the same chart
x Real-time and historical data on the same chart
x Trend third-party data files (csv)
x Trend array points
x Different plotting rates per pen
x Ability to dynamically switch pens
x Separate axis availability for each pen
x Ability to scroll plotted data
x Smooth and step lines
x User-definable labels for pen lines
x Ability to dynamically change trends at runtime
x Quick Trend short-cut menus
From the CIMPLICITY workbench or point control panel, any point on the screen
can be selected for a Quick Trend short-cut menu without pre-configuring the trend.
An ActiveX object and XY plots are available to plot process data. Two or more
variables can be plotted against each other with multiple X or Y axes.

12 x Human-Machine Interface (HMI) GEI-100485D

 Trending with Toolbox and ToolboxST
In addition to the CIMPLICITY trending tools, the HMI contains the trending tools
inherent in the GE controller with which it interfaces. Modern turbine, generator, and
compressor controls are standardized in Control System Toolbox and ToolboxST
software, which are fully integrated with editors for application software,
diagnostics, and so on. Typical trending attributes are shown in the following figure.

Features
Features
z Automatic Upload of Capture Blocks
z Automatic Upload of Capture Blocks
z Micro-second Resolution
z Micro-second Resolution
z Drag & Drop of Variables to Trender
z Drag & Drop of Variables to Trender
z
z
Browser
Browserfor
forVariables
VariablesSelection
Selection
z
z
100’s
100’s of Signalsper
of Signals perTrend
Trend
- -Mask
Mask&&Unmask
UnmaskofofSelected
SelectedVariables
Variables
z
z
Video Type Forward-Reverse
Video Type Forward-Reverse
z
z
Left-Right
Left-RightDrag
DragofofTime
TimeAxis
Axis
z
z
Dual
Dual Cursor (Delta,Min,
Cursor (Delta, Min,Max,
Max,Average)
Average)
z Stacked Traces
z Stacked Traces
z Alarm Messages on Trip Trend
z Alarm Messages on Trip Trend
z Events Log Linked to Trend
z Events Log Linked to Trend
z Export to .CSV
z Export to .CSV

ToolboxST Trend

Security
Security attributes assigned to individual users restrict access to specific operations
and maintenance tasks. A valid user ID and password are required to access
CIMPLICITY HMI functions.
A user’s view determines what resources are available. For example, alarms for
resources outside a user’s view do not display in the Alarm View window.
Emerging international regulations on security are also reviewed and incorporated in
the HMI design. GE software, vendor software, and the integrated system software
are validated for performance and compliance with current security standards prior to
shipment. Several maintenance programs are also available to upgrade the security of
installed systems, as well as for on-going security updates.

GEI-100485D Human-Machine Interface (HMI) x 13

Hardware Options
The HMI consists of hardware from multiple vendors. Constantly changing
technology determines specific details of processor speed, hard drive size, and such.
Hardware Options
Basic component Description
Typical computer Commercial-grade only
hardware
Processor, hard drive, keyboard, mouse, internal
speakers, and so on.
CD-RW and floppy drives
Six USBs; one serial and one parallel port
Ethernet for UDH and PDH
Network interfaces for legacy products as needed (for
example, ARCNET for Mk V/EX2000)
Enclosures Tower
Rack-mount shelf
Monitor options 17” CRT monitor (desktop and panel-mount)
19” CRT monitor (desktop)
21” CRT monitor (desktop)
19” LCD monitor (desktop)
20/21” LCD monitor (desktop)
Dual monitors
Printers Black/white laser
Color laser
Dot matrix (for logging)
Inkjet (8 1/2 x 11)
Other Time synch board with IRIG-B input
Time synch board with GPS receiver
Trackball mouse (standard)

g
14 x Human-Machine Interface (HMI)
GE Energy
1502 Roanoke Blvd.
Salem, VA 24153-6492 USA

+1 540 387 7000

www.geenergy.com
GEI-100485C
Revised 080603
Issued 050307

GEI-100485C
GE Energy
WorkstationST* Alarm
Management Tools fact sheet
GE Energy provides the ControlST* Software Suite for the
operation and maintenance of turbines, generators, heat
recovery steam generators, and balance of plant equipment
in simple cycle and combined-cycle power plants. It includes
a flexible alarm management toolset based on ANSI/ISA-18.2,
Management of Alarm Systems for the Process Industries to assist
in improving the safety, quality, and productivity of the facility.
Embedded WorkstationST* and ToolboxST* applications provide
a user-friendly environment for visualization, navigation, change
management, and analysis of alarm and event conditions with a
common, time-coherent data set for the plant.

Alarm Philosophy
Modern power plant monitoring systems receive an abundance
of plant alarms including those with mission-critical warnings,
indications of abnormalities, nuisance messages, and sometimes
ANSI/ISA-18.2 Alarm Management Life Cycle Model
mere status conditions. Although information is vital to plant
operation, excessive information of varying importance and
vague guidelines for handling it can be detrimental to effective
Data Visualization
plant operation and maintenance. The value of the alarm system depends on the amount and
quality of process data collected, and the manner that it is
To address this problem, GE Energy has convened a council of presented to the user. Alarm states are presented with audible
experts with decades of experience in power plants to create and visual attributes following the guidelines of ANSI/ISA-18.2
and document an alarm philosophy for the FlexEfficiency* and summarized in the following table.
50 combined-cycle power plant. The philosophy is relevant
to any power plant, and it defines the basic objectives of the Alarm State
Audible
alarm management process and the methodology for achieving (ControlST release Visual Indications
Indication
those objectives including the criteria for prioritizing, classifying, V04.04)
measuring and reporting alarms.
Color Flashing
Data Collection Normal No No No
To achieve the best time resolution for analysis, alarms and
Unacknowledged Yes Yes Yes
events are initiated and timestamped in the application software
that is running in the controller. There are five types of alarms Acknowledged No Yes No
and events: process alarms, control diagnostic alarms, events,
Return to
Sequence of Events (SOE), and holds in the startup sequence.
normal state No No No
SOE is a special category of events that provides high resolution unacknowledged
timestamps for contact inputs on the order of ±1 ms, which are
particularly useful in power plants where trips can originate Latched
Yes Yes Yes
from electrical equipment and grid dynamics. In most cases, all unacknowledged
contact inputs in Mark* VIe control systems can be enabled for
Latched
SOE monitoring, which provides a large source of plant data for No Yes No
acknowledged
analysis to compliment traditional alarm management data.
Out-of-service
No Yes No
Data is also collected from WorkstationST servers and third-party alarm
Object Linking and Embedding (OLE) for process control alarm Audible alarm features are available to compliment visual
and event (OPC® AE) servers. This data is then available for displays with Tone, Wave File, and Voice attributes. The alarm
communication to alarm viewers and archiving in historical files. system monitors the highest priority alarm that is active,
unacknowledged, and not silenced, and plays the sound for that
alarm. If Text To Speech is selected, an audible announcement of
the alarm priority, type, and description is provided.

GEA-S1206B
In addition to alarm states, there is a vast amount of alarm An advanced rationalization tool, SILAlarm from exida™ LLC,
information available for analysis. To enhance visualization, is available for integration with the ControlST software suite to
Alarm Properties can be selected from a large menu and then support and document the results of the rationalization process
sorted as displayed in the following table. in a master database. It systematically guides plant personnel
through the process of reviewing, justifying and documenting
Alarm Properties Description the design of each alarm, including:
• Evaluation of consequences and time-to-respond
Acknowledged Acknowledged or unacknowledged state
• Prioritization
Actor ID ID of the user who performed the last action • Document the cause, consequence, confirmation, corrective
Alarm Class Designates the priority, color, flashing, and
action
sound values • Classification
• Setpoint limit determination
Alarm ID Unique alarm identification • Settings of dead bands and on/off time delays
Alarm State Current state of the alarm/event • Alarm suppression/advanced alarming
• Functional safety management
Alarm Type Alarm, event, SOE, diagnostic, or hold • Routing of alarm messages
Description Functional description of the alarm
Device Name Unit name
Device Time Time the alarm was generated by a device

Locked State Locked (L) or unlocked (U) state of an alarm

Override State Overridden (Y) or normal (N) state of an alarm

Plant Area Logical plant area assigned to an alarm

Primary Language Alarm description is in the primary language
Priority Alarm/event priority (1 is highest priority)

Quality Data quality for an alarm or event

Recorded Time Time that the alarm was recorded by the Alarm Prioritization Based on Consequences and Time-to-Respond
alarm system (SILAlarm™)
Second Language Alarm description is in the second language
Reports
Severity Alarm/event severity (1 -to- 1,000)
Configurable alarm report tools are included in the ControlST
Silenced Silenced (Y) or normal (N) state of an alarm software suite to provide guidance for alarm analysis.
Transition Reason Usual reason is normal alarm state change
An Alarm Performance Metric Report summarizes the key
Unit Type Type of unit the alarm was received from performance metrics and their actual values compared to their
target values based on at least 30 days of data. For convenience,
Units Display units for a value
configuration of all metrics in the report can be instantly set to a
Value True/False (Boolean) or the value of an analog predefined set of default values with a single command, or the
alarm configuration can be customized.
Variables Alias User assigned variable name for an event
Individual reports are available for Alarms Per Day, Alarms
Variables Name Variable associated with an alarm/event Per Hour, and Alarms Per 10 Minutes with any combination
of the five alarm/event types. For each report, the data can
To simplify visualization, filters are provided for both real-time be displayed in a tabular format displaying the quantity of
and historical data. Filter collections can contain one or more occurrences for each alarm during the specified period of time.
filters, and each filter can contain one or more Alarm Properties Also, a bar or pie chart can display the alarm quantities and the
as displayed in the preceding table. For example, the Plant Area percentage of alarms above and below a threshold level.
filter is used to filter alarms and events based on the area of
the plant where the alarm occurred. This filter could then be An Alarm Flood occurs when alarms are occurring at a
combined with the Priority filter to passthrough alarms and faster rate than the operator can effectively manage them.
events based on location and priority. ANSI/ISA-18.2 defines an alarm flood period as more than 10
alarms occurring in a 10 minute period. The Alarm Flood report
Alarm Rationalization enables configuration of the number of alarms to begin a flood
During the rationalization stage of the alarm management life condition (normally > 10), to end a flood condition (normally < 5),
cycle, existing and potential new alarms are systematically and the time interval (normally 10 minutes).
evaluated to the criteria in the alarm philosophy. If the alarm
meets the criteria, the alarm setpoint, consequence, and
operator action are documented, and the alarm is prioritized and
classified according to the alarm philosophy.
2 GEA-S1206B
 Typical Most Frequent Alarms Reports

A tabular report displays the quantity of alarms during each To expedite troubleshooting, each alarm help message identifies
alarm flood, the alarm/event type, the start time of the flood, both the probable cause and a recommended corrective
and its duration. A supporting pie chart displays the number of action. Standard alarm help messages are provided for control
alarm floods and the percentage of floods allocated to each diagnostic alarms related to abnormal conditions in the control
of the five alarm/events types. platform such as a relay failure, and process alarm help
messages are available from GE Energy for selected turbine and
Also useful is the knowledge of which alarms occur most often. plant configurations.
The Most Frequent Alarms report provides this data with a table,
a bar chart, and a pie chart report for a specified period of time. Basic Operator Actions and Navigation
In addition, the pie chart displays the percentage of the overall A Live Alarm toolbar simplifies the selection of operator
alarm load that is being allocated to the 10 most frequently commands and navigation between the alarm management
occurring alarms. tools and associated tools, such as the ToolboxST software editor.
Also, a simple right-click in a display area provides a shortcut
Chattering Alarms transition between alarm states in a short menu with additional options. For convenience, unavailable
period of time and are not related to operator actions. These operator actions are listed, but with subdued coloring to indicate
nuisance alarms are problematic since they are often the most that these actions are not suitable in the current alarm state.
frequently occurring in a plant. A table and bar chart provide
information on chattering alarms, which are alarms that typically Operator Actions for All Displayed Alarms (no selection required)
transition three times in one minute.
Menu Item Operator Action
Stale Alarms remain in the alarm state for more than 24 hours Acknowledge All Acknowledges all alarms that are currently
and usually provide minimal useful information. Table and bar On Screen visible on the screen
chart reports are provided for stale alarms.
Reset All on Resets all alarms that are currently visible on
Screen the screen
Alarm Help
The alarm management system provides user help messages for Silence All On Suppresses the sound being annunciated for all
Screen alarms that are currently visible on the screen
process and control diagnostics alarms. Help can be accessed
with a browser, by selecting an individual alarm and then
selecting the Help button, or though the Help item in a shortcut
menu.

GEA-S1206B 3
 fact sheet
Operator Actions for Selected Alarms Benefits
A comprehensive toolset is essential for an effective plant alarm
Menu Item Operator Action
management process. The ControlST alarm management
Acknowledge Acknowledges the selected alarm set toolset may enable:
Unacknowledge Removes the acknowledged condition
• Improved operator effectiveness with advanced analysis
tools to filter mission-critical alarms from nuisance alarms
In Service Returns the selected alarm(s) to In Service • Increased equipment availability with better quality data to
Out of Service Places the selected alarms Out of Service identify emerging malfunctions
• Reduced mean-time-to-repair with more precise alarm data
Lock Prevents the selected alarm set from changing to expedite troubleshooting and repair
Unlock Releases the Lock
Compatibility
Override Alarm override for the selected alarm set
The alarm features described in this document are available with
Remove Override Removes the override ControlST software release V04.04, which can be applied to:
Reset
• Mark VI and Mark VIe Turbine and Plant Controls
Resets the selected alarm set
• Mark VIeS Safety Controllers
Silence Silences the selected alarm set • EX2100e Generator Excitation Controls
• LS2100e Static Starter Controls
Unsilence Reinstates the sound attribute

Silence Alarms Horn Silences the alarm horn of the selected alarm References
set
For additional information reference:
• ANSI/ISA-18.2 Management of Alarm Systems for the Process
Operator Navigation and Support Features Industries
Menu Item Operator Action • GEI-100620, WorkstationST Alarm Viewer Instruction Guide
• GEI-100626, WorkstationST Alarm Server Instruction Guide
Alarm Attributes Displays alarm attributes for the selected • SILAlarm online sales brochure
process alarm http://www.exida.com/images/uploads/SILAlarm_brochure
Alarm Help Provides process and control diagnostic _revise4.pdf
alarm help as previously described.
Alarm Status History Retrieves the set of historical alarms for a
selected time period and filter criteria

Copy Selection Copies the selected alarms into the clipboard.

For pasting into Word® or Excel®

Create Filter from Creates a filter from a set of alarms and

Selection events

Display Variable Displays a data grid with the selected alarm

Attributes variable attributes

Go To Definition in Navigates to the application software block

Logic where the alarm variable originates

Go To Display Screen Navigates to the screen containing the alarm

variable for the selected alarm

Print Alarms Prints all alarms that are currently displayed

or could be displayed if scrolled into view

For further assistance or technical information, contact the

nearest GE Sales or Service Office, or an authorized GE Sales
Representative.

© 2011 General Electric Company, All rights reserved.

* Trademark of General Electric Company
Excel and Word are registered trademarks of Microsoft Corporation.
OPC is a registered trademark of The OPC Foundation.
SILAlarm and exida are trademarks of exida™ LLC.

GEA-S1206B Issued: 2008-09-05 Revised: 2011–10–18

 Alarm Tracing

Mark* Control System

Energy Technical Training

*Trademark of the General Electric Company.

Objectives

Learn how to trace from an alarm to the signal

which is causing the alarm
Learn how to use WorkstationST Alarm Viewer
to view historical alarms, Event’s, SOEs

2
Propriety information for training purposes only
Viewing Alarms

Current Alarms, Events, SOEs and Holds may be

viewed in the Cimplicity alarm portion of an HMI
screen.

3
Propriety information for training purposes only
Tracing an Alarm - 1

The Signal that drives the alarm is listed in the

alarm screen
i.e. Water Injection Not Selected – L30WN_ALM
To trace this signal we will use the Finder

4
Propriety information for training purposes only
Tracing an Alarm - 2

Open the Finder (Ctrl+F)

Enter the alarm signal name i.e. L30WN_ALM
Select Find
5
Propriety information for training purposes only
Tracing an Alarm - 3

Double-click on one of the items in the

Find Results Tab

6
Propriety information for training purposes only
Tracing an Alarm - 4

Select the Where Used Tab

Double-click where the signal is written
(blue pen and yellow pad)
Continue to trace backwards (L83WQ_CMD)
7
Propriety information for training purposes only
Tracing an Alarm - 5

Double-click where the signal is written

8
Propriety information for training purposes only
Tracing an Alarm - 6

Problem is Pin A of Rung_6 (L83WQ_ON_CPB) wet low Nox

selected on.
In this case, an operator error.
Operator did not select wet low Nox control on.
9
Propriety information for training purposes only
Alarm Troubleshooting Procedure
1. Identify and record the alarm signal name
2. In ToolboxST use finder to locate the signal
3. Double-click the find result
4. Use the Where Used tab and find where the
signal is written
5. Continue to trace the signal backwards by
identifying the cause of the signal from a block
input and finding where the signal is written.
6. Locate the origin of the signal or the hardware
point.
10
Propriety information for training purposes only
Alarm Troubleshooting Procedure 2
1. Open WorkstationST Alarm Viewer
2. Identify the active alarm and Right-click it
3. Select Go To Definition in Logic
4. Use the Where Used tab and find where the
signal is written
5. Continue to trace the signal backwards by
identifying the cause of the signal from a function
block input and finding where the signal is written.
6. Locate the origin of the signal or the hardware
point.
11
Propriety information for training purposes only
Tab 25
 g
GEK 111309g
Revised, June 2012

GE Energy

GE Product Safety Recommended Best Practices

Safe Site Work Practices

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

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without prior permission of the copyright owner.
 GE Product Safety Recommended Best Practices GEK 111309g

TABLE OF CONTENTS

I. INTRODUCTION ....................................................................................................................................... 4
II. SCOPE.......................................................................................................................................................... 4
III. GENERAL ................................................................................................................................................... 4
IV. SAFETY OF POWER TRAIN AND ACCESSORIES ............................................................................ 5
A. Safety Critical System Faults................................................................................................................. 6
B. Control System Software Security......................................................................................................... 7
C. Installations Considerations ................................................................................................................... 7
D. Operation Considerations....................................................................................................................... 8
E. Maintenance Considerations................................................................................................................ 10
V. SAFETY SIGNAGE .................................................................................................................................. 14
VI. LOCK OUT TAG OUT (LOTO) ............................................................................................................. 15
VII. PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................................................................... 17
VIII. ENCLOSURE ENTRY PROCEDURES................................................................................................. 18
A. General................................................................................................................................................. 18
B. Permit Entry Areas............................................................................................................................... 19
C. Confined Space Area ........................................................................................................................... 19
IX. PERSONNEL TRAINING ....................................................................................................................... 20
X. STANDARD SIGNAGE FORMAT......................................................................................................... 22

LIST OF FIGURES

Figure 1. Example Warning Sign ......................................................................................................................... 10

Figure 2. General Layout of Safety Signage ........................................................................................................ 22
Figure 3. General Layout of a Multilingual Safety Signage ................................................................................ 23

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without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

I. INTRODUCTION

GE Energy designs its power train and accessories according to International Standards to eliminate or
mitigate hazards to personnel to the lowest practicable levels. The implementation and enforcement of
safe site work practices by the end user is an additional critical element to ensuring all protective
measures have been implemented to reduce residual risk.

Safe site work practices are an important part in supplementing the mitigation of inherent hazards in the
workplace. Safety is a priority on all sites and employers are required to ensure the health, safety and
welfare of their employees by having a plan for orienting and training employees. It is critical that
employers provide safe working procedures to ensure safe work practices and procedures are clearly
written and communicated to employees, and that employees are appropriately supervised to ensure they
are completing tasks safely.

The recommendations within this document are purely from a safety perspective. It is the end user’s
responsibility to use this information in conjunction with the GE Operation and Maintenance Manual
(O&M Manual), site training, policy enforcement, and the accepted industry work practices to assure
employee safety.

II. SCOPE

This document is intended to provide an onsite reference regarding procedures that pertain to
employee/employer safety and their obligations for implementing safe site work practices. The purpose of
this document is to identify safety related work practices in the operation and maintenance of the GE
power train equipment and a brief description of GE recommended or Industry Standard methods to
address these practices. These recommendations have been taken from GE documents or Industrial
Standards/Directives and may not be outlined in whole. For a complete review of the documents,
references of the cited documents have been included.

This document is not intended to be an overall Site Safety Plan. The Maintenance or Plant Safety
Manager should use this document as a source of information to assist in development of site-specific
safe work practices.

This document compiles the safe site work practices and residual risk requirements derived from Product
Safety Risk Assessments for a typical end user in order to maintain safe operation and maintenance of GE
Products. References are made from numerous instructions and precautions quoted in the various GE
supplied documentation, General Industry Practices, Codes and Standards, OSHA and European Union
(EU) Directives.

III. GENERAL

During operation and maintenance of the GE Power Train equipment the employer is expected to
implement and follow stringent safe site work practices as closely as possible. Only trained and
authorized personnel should operate and maintain power plant equipment. All personnel should be
cognizant of potential hazards and should follow sound safe site work practices as outlined by the
International Labor Office – Geneva (ILO) guidelines for Occupational Safety and Health Management
Systems (OSHMS) ILO-OSH-2001 or article 6 of the 89/391/EEC directive or the Occupational Safety
and Health Administration OHS Act of 1970 General Duty Clause Sec 5.

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without prior permission of the copyright owner.
GE Product Safety Recommended Best Practices GEK 111309g

General safe site work practices include:

• Adhering to GE product service notices or technical information recommendations

• Practices that tend to eliminate the hazard/risk

• Practices that control the hazard/risk at source, through the use of engineering controls or
organizational measures

• Practices that minimize the hazard/risk by the design of safe work systems, which include
administrative control measures, analyzing the hazards/risk and recording hazardous events

• Where residual hazards/risks cannot be controlled by collective measures, the employer should
provide for appropriate personal protective equipment, including clothing, at no cost, and should
implement measures to ensure its use and maintenance

• Lock out Tag out (LOTO) procedures be followed by all personnel on site on a regular basis.

• Ensuring employees have safe access to heights through properly designed platforms, scaffoldings,
fall protection tie-offs, etc.

• Ensuring that only employees with proper training and with proper equipment should perform any
task at site

• Personnel interactions with equipment and compartment are conducted in a safe manner

• Ensuring employees are knowledgeable and accessible to Material Safety Data Sheets

• Training of operators to appropriately respond to warning alarms

IV. SAFETY OF POWER TRAIN AND ACCESSORIES

Product Safety Engineering at GE strives to mitigate the occupational risks of GE Power train equipment.

Risk of personnel injury during the design life of the equipment is evaluated as part of the design process.
It is important to recognize that the end user of the equipment will operate their plant in a unique manner.
Design life of the equipment is based on cycles (starts) and accumulated operating time (hours). Risk
assessments are performed assuming a uniform distribution of starts/hours. Over the life of the unit, total
risk accumulated of a peaking unit will be the same as a non-peaking unit. However, a unit operating in
peaking mode (high starts/hour), will accumulate risk faster. It is important to adhere to the design limits
of both cycles and hours to avoid unacceptable safety risk.

Through the residual risk summaries, GE specifies the risks associated with the installed equipment and
expects the end users to mitigate each of them. These risks may be at the installation, operation or
maintenance stages and, by employing safe site work practices, these risks can be further mitigated or
completely avoided.

Below are some of the practices to be followed as drawn from the Residual risk summaries.

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without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

A. Safety Critical System Faults

It is critical to take appropriate action upon the detection of a fault (by diagnostic tests, proof tests,
instrumentation or any other means) in any safety critical system.

• In case of a single fault in a system with redundancy, shutdown at earliest opportunity and
prevent continued operation until the system is restored.

• In case of a single fault in a system with no redundancy or multiple faults, immediately shut
down and prevent continued operation until the system is restored.

Examples of Safety Critical Systems:

Axial position* (Steam Turbine)

Compartment ventilation* (Gas Turbine)

Emergency overspeed protection* (Gas and Steam Turbine)

Emergency stop push button* (Gas and Steam Turbine)

Excess firing fuel flow* (Gas Turbine)

Exhaust purge timer* (Gas Turbine)

Exhaust spread monitor (Gas Turbine)

False start drain* (Gas Turbine)

Fire protection system* (Gas Turbine)

Flame detection* (Gas Turbine)

Hazardous gas protection* (Gas Turbine)

Hydrogen Monitoring System (Generator)

Inadvertent Energization (Generator)

Loss of lube oil* (Steam Turbine)

Loss of Seal Oil (Generator)

Sequential Trip (Steam Turbine)

Vibration protection* (Gas and Steam Turbine)

Recommendations for maintenance of these safety critical systems are found in the O&M manual.

*For IEC 61511 compliant units, additional maintenance and testing requirements for these systems
are identified in the Safety section of the O&M Manual.

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without prior permission of the copyright owner.
GE Product Safety Recommended Best Practices GEK 111309g

WARNING

UNDER NO CIRCUMSTANCE IS IT PERMISSIBLE TO OPERATE

WITH ANY SAFETY RELATED TRIP, SHUTDOWN, OR
START-INHIBIT DEFEATED OR DISABLED.

B. Control System Software Security

No changes or adjustments (other then calibration) can be made to Safety Critical Systems without
written approval from a GE Design Engineer. Making any unauthorized changes to safety systems in
the controls could put equipment and personal at unacceptable risk.

A system check as per the pre startup check procedures should be conducted to maintain all settings
at normal position.

C. Installations Considerations
It is important for the customer to install the equipment and systems as specified by GE and as per
the Industry Standards.

Before beginning any installation activities compare the equipment to the applicable system
schematics for the project and verify that the hardware matches the schematics.

It is a best practice to refer to GE supplied documentation or Industry Standards while installing any
equipment. Typical common installation considerations experienced at sites are:

• Proper Welding procedures should be followed on site.

• Provide adequate draining for all systems wherever applicable.

• Installation of pipes, which may contain hot gases or fluids and result in a potential source of heat
to personnel, should meet the specifications for insulating with block material, covers, blanketing
and/or guards.

• Permanent structures or walkways that provide access to areas that contain hot surface should
meet specifications for providing adequate guards or other means to prevent personnel contact
with the hot surfaces.

• Hot exhaust should be safely routed away from personnel and equipment to prevent the risks of
overheat hazards.

• Procedures to replace parts should follow the respective standards applicable for the parts.

• A safe area should be defined by hazardous area maps to prevent the contact of potential
hazardous vapors with personnel or ignition sources.

• The installer should make use of proper stud heating procedures for the tightening and
installation of studs.

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without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

• Vents should be installed to avoid contamination present in other vents and if necessary separate
vent should be installed. Vents should be protected from the weather and fitted with flame
arrestors or wire mesh if necessary. Vent should be so located as to prevent accidental discharge
of vapors and gases with fires and sparks.

• Follow the installation and testing procedures for the mounting of instrumentation that monitor
key functions or that are mounted in hazardous locations such as exhaust thermocouples on a gas
turbine.

• Lighting should be provided throughout plant site to maintain adequate visibility. Such lighting
should not interfere with the visibility of warning lights and probes.

D. Operation Considerations
1. Pre-Startup Checks

• Before operating the turbine, personnel on site should perform checks to ensure the proper
functioning of all systems. This includes:

• A detailed procedure for functional tests of all control systems such as electrical trip,
overspeed trip, voltage monitoring, lubrication pump monitors, valve operation, fire
protection, hazardous gas protection, etc., should be conducted.

• Proper Leak checks should be carried out on all piping, flanges, and connections.

o Refer to GEK 28126 for Leak Detection and Test Procedures for Fuel Gas Piping.

• Refer to GEK 111694 for Inspection and Maintenance Recommendations for Handling and
Inspection of Flexible Metal Hoses.

• Inspect equipment and the related auxiliary systems during pre-start checks.

• Verify that emergency backup and trip systems such as the oil pumps, emergency trip
systems, emergency lighting, and the emergency power supply, are in good working order.

• Before operation, the calibration of all protection system sensors should be verified.

• If starting the system after a maintenance outage check all systems which had LOTO
implemented to assure they have been properly restored.

• Prior to operating any equipment, make sure that all maintenance activities have been
completed and that no personnel are present in the maintenance area.

• Refer to GEK 116445 for gas turbine operational best practice troubleshooting guidelines for
gas fuel systems

2. Post startup checks

Operating conditions should be verified to be within design limits. Maintaining design limits for
pressure, temperature, steam purity, oil viscosity, etc., are the end users responsibilities.

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without prior permission of the copyright owner.
GE Product Safety Recommended Best Practices GEK 111309g

3. Remote starting of equipment.

Much of the equipment along the power train is started remotely or automatically. Employees
must be made aware as to which equipment can be started remotely. If work is to be conducted
on any of the equipment, LOTO must be followed.

4. Shutdown of power train

Every shutdown of the power train commands energy isolation to the turbine. This is usually in
the form of gas fuel, liquid fuel, and/or steam isolation. In rare circumstances, plants have
experienced multi-point failures in the steam or fuel system that allowed continued flow of
energy to the turbine AFTER a trip or shutdown command. In this circumstance the turbine
continues to create power, there for it is critical to keep the turbine connected to the load (grid,
compressor, etc) until all energy sources are isolated. Isolation of energy in this circumstance
must be done based on plant-specific system configuration (closure of manual steam isolation
valves in extractions, boiler, safety shut-off valves, etc). Failure to confirm energy isolation prior
to removing load from the power train may result in destructive overspeed of the power train. GE
recommends verifying the following control mechanisms are in place to mitigate this potential
circumstance:

• Maintenance of energy isolation system: Verify maintenance and testing programs are in
place per Inspection and Maintenance (I&M) manual recommendations for critical elements
of the energy isolation system. Example critical elements:

1) Stop and control valves (stroke tests, leak tests, repair / refurbishment intervals)
2) Check valves (stroke tests, repair / refurbishment intervals)
3) Trip solenoids (inspection, testing)
4) Hydraulic fluid (sampling / analysis, check for water content)
5) Overspeed system (mechanical, electrical, trip testing)

• Automated protection systems in place: Verify shutdown sequence of all power train
equipment confirms energy isolation prior to load removal (sequential tripping).

• Human factors: Recent incidents indicate personnel do not always respond appropriately to
failure to isolate energy during shutdown. GE recommends implementing measures to warn
personnel to confirm energy isolation to the power train prior to manually removing load.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

1. GE recommends implementing appropriate warnings on all manual load removal devices

(see figure 1 below for example signage). GE also recommends considering factors to make
this warning more effective such as:
a. Implementation of a covered switch to make load removal a 2 step operation
b. Activation of a warning strobe upon opening of the cover to the switch

Figure 1. Example Warning Sign

2. Implement warnings and/or appropriate acknowledgements in any control system interface
(such as DCS) that is capable of forcing removal of load from the power train.
3. Conduct appropriate operator training as required by site-specific conditions.
4. Develop site-specific checklist to identify and verify isolation of energy prior to load
removal.
5. Noise

Where required by local legislation a declaration should be provided detailing the airborne noise
emission based upon measurements made using the method defined in ISO 10494:1993. The
declaration shall comply with ISO 4871:1996.

E. Maintenance Considerations
1. Maintenance Precautions

During maintenance operation the end user should consider the following issues:

• Only authorized personnel should perform maintenance and repair on GE equipment. If

personnel are required to perform routine maintenance, proper procedures should be
followed by personnel who are trained and familiar with the maintenance tasks.

• Maintenance within confined space should follow proper Confined Space Entry Permit
Procedures as outlined by applicable international codes and standards.

• Maintenance within compartments that have been identified with having the potential for
significant hazards should follow proper Compartmental Entry Permit Procedures. (See
section VIII).

• During repairs of equipment that may collect hazardous gases (i.e. hydrogen, natural gas,
methane, carbon dioxide) precautions should be taken to vent, purge and/or LOTO to avoid
explosion and asphyxiation hazards. (Some examples of such equipment are hydrogen
coolers, valves and piping, CO2 fire protection systems, etc.)

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without prior permission of the copyright owner.
GE Product Safety Recommended Best Practices GEK 111309g

• When spraying Electric Epoxy paint on the generator armature and windings care should be
taken to avoid possible ignition of paint by spark of flame or excessive heat of any kind.

• Proper precaution should be taken while entering compartments where a CO2 Fire protection
system has been discharged until the CO2 concentrations have dissipated and CO2
concentrations are at safe level.

• Drain all modules/skids before attempting to lift.

• When a unit is not in operation due to maintenance, personnel may perceive conditions are
less hazardous than during normal operation. To prevent inadvertent release of fuel or stored
energy of any source, such as mechanical, hydraulic or electric from equipment and/or
motors near the impacted scope of work, personnel must follow adequate safe site work
practices with the same diligence as during normal operation.

• The end user should maintain fluid quality (secondary steam, water, fuel) as per
specification.

2. Leaks

Pressurized joints may give way to high-pressure leaks that may not be visible or audible to
personnel. Personnel should take proper precautions while performing their duties where
high-pressure hazards may exist. Operators should frequently inspect for indications of leaks and
proper operation of safety devices. Personnel should be trained on required actions and warned
of the hazards of invisible leaks such as those of superheated steam.

The location of leaks can be confirmed with the use of thermal imaging cameras.

Refer to GEK 28126 for Leak Detection and Test Procedures for Fuel Gas Piping.

3. Housekeeping

Good housekeeping is essential for safe plant operation by maintaining a clean and orderly
workplace. Cleaning and containing oil spills, maintaining clear entry and egresses, and
maintenance of walkways and ladders will prevent the occurrence of safety hazards.

• Floors, platforms and other walkways should be kept free of oil, grease, water, and other
slippery materials,

• Stairways, aisles, exits, walkways and work areas should be kept free of debris and other
obstructions,

• After maintenance activities have been completed, residual oils, coolants and other slippery
material may still be present in the compartments and care should be taken eliminate such
hazards.

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without prior permission of the copyright owner.
GEK 111309g GE Product Safety Recommended Best Practices

4. Electrical Maintenance

Electrical panels, motor controllers, control systems include equipment that contain a potential
hazard of electrical shock or burn. External sources of power may be present in the panels that
are NOT switched by the control power circuit breaker(s). Before handling or connecting any
conductors to the equipment, use proper safety precautions to ensure all power is turned off.

All electrical energy sources to the Unit control panel should be isolated and the system should
be drained of all energy before grounding is to be carried out per procedure defined in unit
control panel documentation.

5. Mechanical Maintenance

Coupling guards, fan guards or other devices protecting personnel contact with rotating or
moving parts that were removed for maintenance should be replaced following the maintenance
activity to ensure adequate protection has been restored.

Any insulation and other safe guards on piping, valves, casings or any hot surface should be
replaced after completion of the maintenance activities to ensure adequate protection has been
restored.

6. Rigging, Hoisting and Jacking

Rigging should be conducted by trained personnel and follow the lifting instructions outlined in
the O&M manual for proper lifting. If proper guidelines are not available in the O&M Manual
then the site personnel should follow the standard safe site work practices as outlined by the
applicable codes and standards. Prior to use, all rigging equipment should be inspected and
tagged as required. Personnel must not stand or walk under any load. Loads should not be left
suspended unless an authorized person in attendance.

7. Calibrations

There are several systems that rely on routine calibration to ensure continued accurate
monitoring and protection:

• Combustible gas detectors

o Follow gas detector supplier recommendations for calibration. Appropriate caution

must be taken to take into account not only the different LEL data but also the
different response curves of the sensors as discussed in ASME paper
GT2005-68875.

• Fire detectors

• CO Sensors

• UV detectors

• Heat detectors

• Pressure sensors

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GE Product Safety Recommended Best Practices GEK 111309g

• Temperature sensors

• Positioning sensors

• Seismic sensors

It is recommended that each site develop an adequate calibration interval for these sensors. In
many cases, the interval between calibrations will be dependent on local conditions (air pollution
levels, ambient temperatures, humidity, etc). For this reason, it is recommended that the end user
perform the calibration for each sensors/detectors as per the O&M Manual or the specifications
provided by the manufacturer of these sensors.

8. Working Inspection

During normal operation, the site management should develop a plan to conduct working
inspections of equipment and interconnect piping in a safe manner utilizing safe site work
practices such as LOTO, Confined Space Entry, Permit Entry, etc.

9. Pressure Relief Devices

Pressure relief devices are devices provided for overpressure protection of a pressurized system.
These are devices such as pressure safety valves, safety valves, pilot valves, and rupture disks.
These devices are designed to intervene when normal control measures have failed to prevent
pressure from increasing to the point of compromising system integrity. Proper installation,
inspection and maintenance of these devices is required to ensure their availability to prevent a
critical overpressure condition. Installation, inspection and testing requirements include:

1. Measures taken to ensure device is functioning upon installation [removal of any test plugs /
covers, ensure device was properly stored (inlet/outlet covered to prevent foreign material
blockage), verify proper device setting / application per P&ID, etc]
2. Periodic inspection of device condition and installation (evidence of leak-by, deposits on
device, rust, corrosion, damage, test gags not removed, etc)
3. Testing and operational inspection [periodic testing per code requirements and consistent
with site experience with this type of application (if test failures observed, tighten testing
interval to ensure device is maintained in an operational condition before onset of fouling,
etc)]
4. Refer to National Board Inspection Code • Part 2 – Inspection: section 2.5 Pressure Relief
Devices for detailed inspection, testing, and test frequency recommendations.

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GEK 111309g GE Product Safety Recommended Best Practices

V. SAFETY SIGNAGE

Safety Signage is required to warn personnel of hazards anytime the existing equipment design, guarding,
or other engineering controls cannot adequately mitigate the risk of injury or illness. Wherever feasible,
signs must be used to control hazards before resorting to administrative controls such as training,
manuals, experience, etc. Customer should ensure that all the personnel on site adequately understand all
signs.

Safety signs must include the following five standard components.

• Safety Signal Word appropriate for sign hazard classification,

• Corresponding Safety Alert Symbol,

• Specific Hazard identification,

• Safety Message panel, and

• Appropriate Safety Symbol/Pictorial.

For guidelines regarding the colors, fonts, symbols, brevity of language and placement of signs the
customer should refer to the ANSI Z535.1-ANSI Z535.5, IEC 80416, ISO 3864, ISO 3461 92/58/EEC
and or any other region specific industry standard.

• Whenever the topic of a sign can be conveyed by one of the symbols provided in ISO 3864 Annex B,
the ISO symbol should be used. If the topic of the sign cannot be adequately expressed by one or a
combination of the symbols provided in ISO 3864 Annex B, one of the symbols provided in ANSI
Z535.3 (8) should be used. If neither source contains an appropriate symbol, a new symbol may be
designed. ANSI Z535.3-1998 (6) ISO 3461, and IEC 80416-1 (7) provide helpful recommendations
for designing new symbols. Additionally, Directive 92/58/EEC is mandatory for safety signs within
European Union.

• Signs should be placed in the immediate vicinity of the hazard in such a way that maximizes their
visibility. The placement should provide a safe viewing distance, which permits a reasonable hazard
avoidance reaction time.

• If it is determined that multi-lingual signs are necessary, signs with 3 sections set horizontally shall
be provided. The center section will contain the Safety Symbols/Pictorials. The left section will
contain the Safety Signal Word, Safety Alert Symbol, Specific Hazard, and Safety Message written in
the local or other appropriate language. The right section will contain the Safety Signal Word, Safety
Alert Symbol, Specific Hazard, and Safety Message written in English as depicted below.

• The signage used should also indicate type of Personal Protective Equipment (PPE) to be used near
the demarcated hazardous area.

• Use of different colors, appropriate lighting in and around compartments and machinery is a good
practice that customers should follow to complement signage.

• All personnel at a site whether they be employee, operators, contractors or visitors should receive
appropriate training.

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GE Product Safety Recommended Best Practices GEK 111309g

Most common safety signage necessary at the site of power plants is:

• Excessive Noise

• High Voltage

• Hot surface

• Hazardous Atmosphere

• CO2 Hazards

• Confined space

NOTE

The industry safe site work practices require that the plant owners/operators
conduct a signage survey to identify site specific requirements. GE does not provide
site specific signs.

VI. LOCK OUT TAG OUT (LOTO)

Lock out/Tag out (LOTO) is a process of isolating or controlling or safeguarding any machinery or
source of hazardous energy that any operator/employee/user may encounter while manufacturing,
operating, maintaining, or decommissioning of the machinery.

It is the responsibility of the site management to develop appropriate LOTO procedures and train all
employee/personnel to follow them. Refer to EU directive 89/391/EEC or US OSHA Section 1910.269
Subpart S for LOTO recommendations.

OSHA 29 CFR 1910.147 App A provides a detailed outline for typical LOTO procedures.

Typical Procedure to be followed when LOTO is implemented.

1. Notify all affected employees that servicing or maintenance is required on a machine or equipment
and that the machine or equipment must be shut down and locked out to perform the servicing or
maintenance.
2. The authorized employee should refer to the company procedure to identify the type and magnitude
of the energy that the machine or equipment utilizes, should understand the hazards of the energy,
and should know the methods to control the energy.
3. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress
the stop button, open switch, close valve, etc.)
4. De-activate the energy isolating device(s) so that the machine or equipment is isolated from the
energy source(s).
5. Lock out the energy isolating device(s) with assigned individual lock(s).
6. Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating
flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or
restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

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GEK 111309g GE Product Safety Recommended Best Practices

7. Ensure that the equipment is disconnected from the energy source(s) by first checking that no
personnel are exposed, then verify the isolation of the equipment by operating the push button or
other normal operating control(s) or by testing to make certain the equipment will not operate.

CAUTION

Return operating control(s) to neutral or "off" position after verifying the isolation of the
equipment.

Typical Procedure to be followed in a release of LOTO.

1. Check the machine or equipment and the immediate area around the machine to ensure that
nonessential items have been removed and that the machine or equipment components are
operationally intact.
2. Check the work area to ensure that all employees have been safely positioned or removed from the
area.
3. Verify that the controls are in neutral.
4. Remove the lockout devices and reenergize the system.
Note: The removal of some forms of blocking may require reenergization of the machine before safe
removal.

5. Notify affected employees that the servicing or maintenance is completed and the machine or
equipment is ready for used.

Exceptions in Lock Out

Tag out should be used as an alternative to Lock out only if it is not possible to implement Lock out. The
Tag out should provide the same degree of safety as Lock out while enabling employees to conduct
maintenance, live or otherwise, without being exposed to unexpected energization or activation of the
equipment.

Reference: OSHA 29 CFR citation 1910.269(d)(2)(ii)(A)

Appropriate use of LOTO

1. LOTO at Electrical Devices

While any employee is exposed to contact with parts of fixed electric equipment or circuits, which
have been de-energized, the circuits energizing the parts should be isolated.

Safe procedures for de-energizing circuits and equipment should be determined before circuits or
equipment are de-energized.

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 GE Product Safety Recommended Best Practices GEK 111309g

2. LOTO at Fire Protection Systems

National Fire Protection Agency–12 recommends systems should be locked out under the following
conditions:

• When persons not familiar with the system and their operation are present in a protected space.

• When persons are present in locations where discharge of the system will endanger them, and
they will be unable to proceed to a safe location within the time delay period for the system

3. LOTO at Mechanical Devices

• Machinery should be isolated, disengaged or disconnected in order to prevent accidental
movement/motion of parts.

• Never attempt to engage the turning gear unless the turbine rotor is at rest as indicated by the
zero speed light on the turning gear panel.

• Proper Mechanical LOTO of the turning gear will prevent unplanned operation and thus
potential injuries during rotor maintenance, ensure that all personnel are clear of the rotor and its
associated rotating parts prior to jogging the rotor with the turning gear; Reference 89/391/EEC.

Recommended list of Systems that should follow LOTO:

Fuel Systems

Fire Protection System

Electrical Systems

Hydraulic systems Rotating Mechanisms (i.e. Turning Gear)

Steam Systems

VII. PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal Protective Equipment (PPE) is defined as “all equipment designed to be worn or held by the
worker to protect him against one or more hazards likely to endanger his safety and health at work, and
any addition or accessory designed to meet this objective. This excludes normal working clothes,
equipment for emergency and rescue, PPE for military, police or other public order agencies, and
equipment as such.”

An Employer, who requires employee/personnel to perform routine maintenance and/or servicing on a

machine, must provide employee safeguarding and PPE.

Reference: 89/656/EEC and OSHA 29 CFR 1910 Subpart I – PPE and 29 CFR 1910.95 occupational
noise exposure or Subpart G.

Various country specific regulatory documents require personal protective equipment to be used when the
risks cannot be avoided or sufficiently limited by technical means of collective protection or by measures,
methods or procedures of work organization.

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 GEK 111309g GE Product Safety Recommended Best Practices

All PPE should conform to the more stringent of either local or national safety standards. The employer
must enforce strict policies that should be followed by all personnel at site. The PPE must be rated
accordingly to the severity of the hazard and must follow industry standards.

Article 89/656/EEC Annex II provides a non-exhaustive list of personal protective equipment for
protection of portions of body up to and including Whole Body protection. Typical PPE
recommendations are:

Clothing

Protective clothing of appropriate design to resist flame or high heat exposure

Fall

Fall protection equipment, safety harness, etc.

Eyes

Protective eyewear (safety glasses w/ side shield, goggles, etc.)

Head

Protective headwear (helmets, caps, etc.)

Foot

Protective footwear (steel toe shoes, insulating shoes, boots, etc.)

Hands

Protective gloves of appropriate design to resist injury to hands

Ears

Hearing protection (earmuffs, ear plugs, etc.)

VIII. ENCLOSURE ENTRY PROCEDURES

A. General
Personnel entering compartments/enclosures must be aware of the risk and take the proper
precautions to prevent the risk of injury. Personnel should exercise extreme caution when working in
or near compartment/enclosures, which deal with fuel handling systems, or compartments/enclosures
that can have identified risk resulting, in high temperature/heat stress environments, hot components,
high noise, potential for catastrophic failure of rotating components, pressurized components, moving
components, lack of oxygen for life support from a fire protection system, or the potential for leaking
fuel or other gaseous leaks.

Opening of the enclosure doors and any subsequent entry should be under the control of a written
permit to work (PTW) system, which shall also detail PPE suitable for the given task

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GE Product Safety Recommended Best Practices GEK 111309g

B. Permit Entry Areas

GE recommends permit entry procedures are followed for compartment/enclosures where it is
necessary for personnel to enter areas that present hazards to personnel and where these areas may
not be designated as a Confined space.

Permit entry areas should not be entered unless absolutely necessary. Consider all options to carry out
the work activities remotely without having to enter into the enclosure. When it is necessary to enter,
exercise caution when opening and entering the compartment. At no time should entry be permitted
during operation to troubleshoot alarms or abnormal conditions. It should not be permissible to be in
the compartment during starts or changing of speeds or other operating conditions.

Process should include

1. Use an entry permit system, assess the hazards, properly de-energize and LOTO as appropriate.

2. Only trained and authorized personnel should enter the enclosure.

3. Verify proper ventilation is operating properly. Upon ventilation failure immediately exit the
compartment.

4. Ensure the doors for accessing the compartment are restrained in the fully open position with
clear exit paths.

5. Establish an attendant to maintain constant visual/voice contact and voice communication with
the control room operator.

6. Air samples should be taken prior to entry to test for oxygen content and monitored while
personnel are within the compartment.

7. Personnel should wear the appropriate personal protective equipment and clothing.

8. Attendant should be trained in site emergency procedures such as an emergency rescue plan,
recognition of behavior signs of oxygen deprivation, intoxication, heat stress, and trained in the
use of portable fire protection.

OSHA 29CFR part 1910.146(b) provides information involved with compartment safety.

C. Confined Space Area

Pursuant to OSHA 29CFR 1910.146(d)(3), the means, procedures, and practices necessary for safe
permit space entry operations for confined spaces must be developed and implemented. If acceptable
entry conditions cannot be maintained to protect the entrant from hazards during entry, then entry
cannot be authorized.

A gas turbine and exhaust duct shall be considered a permit-required confined space. The permit
space contains such hazards as hydraulically operated diverter dampers, rotating last stage turbine
blades, no lighting, high pressure natural gas fuel supply, and liquid fuel oil supply to the combustion
turbine.

The exhaust duct or any other space with a potential hazardous atmosphere hazard may only be
reclassified as a non permit entry, per OSHA 29CFR part 1910.146(c)(7), if the fuel is isolated by
double block and bleed. Double block and bleed is the closure of a line, duct, or pipe by closing and
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GEK 111309g GE Product Safety Recommended Best Practices

locking or tagging two in-line valves and by opening and locking or tagging a drain or vent valve in
the line. GE recommends that the valves and control system are locked-out during isolation.
Additionally, an alternative means that addresses a fluid flowing through pipes are blanking or
blinding, misaligning or removing sections of lines, pipes, or ducts.

In addition, the exhaust aft diffuser is located between the exhaust frame and the AO42 duct. The aft
diffuser has three hollow struts which connect the diffuser outer barrel to the diffuser inner barrel and
No 2 bearing area. Two of the struts serve as conduits to rout No.2 bearing lube oil piping and
accessory equipment piping from the inner barrel out to the balance of plant connections. The third
strut acts as a vent and is left empty.

This empty strut was not designed as a means of access to the load tunnel. The proper entry point to
inside the inner barrel is through the access man-way on the aft end of the Inner barrel which requires
accessing another access man-way typically located in the HRSG.

IX. PERSONNEL TRAINING

Various country specific standards such as (OSHA 29 CFR 1910.269 and EU directives) require the
employer to train all affected employees/personnel in the purpose and use of energy control (“LOTO”)
procedures. The standards also state that it is the responsibility of the plant owner to be aware of all
hazards on site and to provide for personnel the training and general awareness regarding safety
procedures, Personnel Protective Equipment (PPE) and safety signage of all the hazards to the
employees/personnel/operators on site.

Employees should be trained and be familiar with the safety-related work practices, safety procedures,
and other safety requirements that pertain to their respective job assignments. Employees should also be
trained with any other safety practices, including applicable emergency procedures (such as pole top and
manhole rescue) that are related to their work and are necessary for their safety.

Qualified employees should also be trained and competent in:

• The skills and techniques necessary to distinguish exposed live parts from other parts of electric
equipment,

• The skills and techniques necessary to determine the nominal voltage of exposed live parts,

• The minimum approach distances specified in this section corresponding to the voltages to which the
qualified employee will be exposed, and

• The proper use of the special precautionary techniques, personal protective equipment, insulating and
shielding materials, and insulated tools for working on or near exposed energized parts of electric
equipment.

The employer should determine, through regular supervision and through inspections that each employee
is complying with the safety-related work practices.

Reference: OSHA 29 CFR Citation 1910.269(a)

Safety Signage Training

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GE Product Safety Recommended Best Practices GEK 111309g

GE supplies various hazard warning signage with the equipment. Based on the installation of all various
subsystems, it is the end users responsibility to provide safety signage to warn of potential hazards and
should provide PPE when required.

All affected personnel should be trained about the implications of all the safety signage. The personnel
should be made aware of how to identify each type of warning signal from horns and probes.

LOTO Training

The employees/personnel should be instructed in the purpose of the LOTO procedure to be used. For
example:

• Recognition of hazardous energy.

• Type and magnitude of energy found in the workplace.

• The means and methods of isolating and/or controlling energy.

• The means of verification of effective energy control, and the purpose of the procedures to be used.

• Appropriate LOTO procedures and its importance.

• Procedures for the control of hazardous energy including shutdown, equipment isolation,
lockout/tag-out application, and release of stored energy, verification of isolation; certification of
periodic inspections and certification of training.

• All other employees who may be affected by the energy control procedures should be instructed
about the procedure and the prohibition relating to attempts to restart or reenergize such machines or
equipment.

PPE Training

The employer should provide training to each employee who is required by this section to use PPE. Each
such employee should be trained to know at least the following:

• When PPE is necessary;

• What PPE is necessary;

• How to properly don, doff, adjust, and wear PPE;

• The limitations of the PPE; and,

• The proper care, maintenance, useful life and disposal of the PPE.

Reference: OSHA 29CFR Citation 1910.132(f)

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GEK 111309g GE Product Safety Recommended Best Practices

Asphyxiating Atmospheres

Carbon dioxide, Nitrogen and other gases create an atmosphere that will not support life. It is extremely
hazardous to enter the compartments until asphyxiants have been discharged. Anyone rendered
unconscious must be rescued as quickly as possible and resuscitated immediately. It is essential that
personnel be adequately trained as to the proper action to take in case of such an emergency.

Industry Specific Training

The power generating plant operates at high temperatures and pressures. There are numerous systems that
require cooling, dilution ventilation, lubrication etc. All employees on site should be made aware of the
importance of each system and should be trained of the safety related concerns and measures to be
adopted for reacting to any such system failure or warning alarms. Untrained employees should be made
aware of the people to be contacted and the process of immediately alerting the person in charge. A
safety-oriented attitude should be encouraged at work.

X. STANDARD SIGNAGE FORMAT

Figure 2. General Layout of Safety Signage

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GE Product Safety Recommended Best Practices GEK 111309g

Figure 3. General Layout of a Multilingual Safety Signage

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GEK 111309g GE Product Safety Recommended Best Practices

g GE Energy
General Electric Company
www.ge-energy.com

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 1 of 32

GEK 116689A

g
November 2014

GE Power & Water

Unit Operation - Turbine (Gas)

7F.03, 7F.04 & 9F.03

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
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without prior permission of the copyright owner.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 2 of 32

GEK116689A Unit Operation - Turbine (Gas)

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 3 of 32

Unit Operation - Turbine (Gas) GEK116689A

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to ensure correctness

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage

***WARNING***

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 4 of 32

GEK116689A Unit Operation - Turbine (Gas)

TABLE OF CONTENTS

I. REFERENCE DATA AND PRECAUTIONS ..........................................................................5

A. Operator Responsibility.........................................................................................................6
1. Respond to Annunciator /Alarm Indicators............................................................................6
2. Check of Control Systems .....................................................................................................6
3. Monitor Exhaust ...................................................................................................................6
B. Turbine Controller Unauthorized Access and Modifications..................................................6
C. General Operating Precautions ..............................................................................................7
1. Temperature Limits...............................................................................................................7
2. Pressure Limits .....................................................................................................................8
3. Vibration Limits....................................................................................................................8
4. Load Limit, Overloading of Gas Turbine, Facts Involved and Policy.....................................8
5. Fire Protection System Operating Precautions .......................................................................9
6. Combustion System Operating Precautions ......................................................................... 10
7. Radio transmissions ............................................................................................................ 12
II. PREPARATIONS FOR NORMAL LOAD OPERATION.................................................... 12
A. Standby Power Requirements.............................................................................................. 12
B. Checks Prior to Operation ................................................................................................... 13
C. Checks during Start Up and Initial Operation ...................................................................... 15
1. Crank Mode ........................................................................................................................ 15
2. Fire Mode ........................................................................................................................... 16
3. Automatic ........................................................................................................................... 18
III. OPERATING PROCEDURES ............................................................................................... 19
A. General ............................................................................................................................... 19
B. Start-Up .............................................................................................................................. 19
1. General ............................................................................................................................... 19
2. Starting Procedure............................................................................................................... 19
C. Synchronizing ..................................................................................................................... 21
1. Manual Synchronization ..................................................................................................... 21
2. Automatic Synchronization ................................................................................................. 21
D. Normal Load Operation ...................................................................................................... 22
1. Manual Loading.................................................................................................................. 22
2. Automatic Loading ............................................................................................................. 23
E. DLN System Operation....................................................................................................... 23
1. General ............................................................................................................................... 23
2. Gas Fuel Operation ............................................................................................................. 23
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DWG Number GEK116689 Rev A Released 11/24/2014 Page 5 of 32

Unit Operation - Turbine (Gas) GEK116689A

3. Inlet Guide Vane Operation (IGV) ...................................................................................... 23

4. Inlet Bleed Heat .................................................................................................................. 24
F. Shutdown, Cool down and Restart....................................................................................... 24
1. Normal Shutdown ............................................................................................................... 24
2. Emergency Shutdown ......................................................................................................... 24
3. Cool down .......................................................................................................................... 24
4. Guidelines for Idle Rotor with Hot Unit .............................................................................. 25
5. Unit Re-Start....................................................................................................................... 26
G. Special Operations .............................................................................................................. 26
1. Fuel Transfer (Gas-Distillate Option) .................................................................................. 26
2. Automatic Fuel Transfer On Low Gas Pressure (Gas-Distillate Option) .............................. 26
3. Testing the Emergency DC Lube Pump............................................................................... 26
4. Annual Trip Test ( previous overspeed Test) ....................................................................... 26
5. Temperature Matching ........................................................................................................ 28
6. Water Washing System Operation....................................................................................... 28
7. Unit Operation After Failure to Fire on Liquid Fuel ............................................................ 29
IV. DESCRIPTION OF PANELS AND TERMS......................................................................... 29
A. Turbine Control Panel (TCP) .............................................................................................. 29
B. EMERGENCY STOP (5E) ................................................................................................. 29
C. HMI .................................................................................................................................... 30
1. Main Startup Display .......................................................................................................... 30
2. Master Reset Target ............................................................................................................ 31
D. Definition of Terms............................................................................................................. 31
E. Supervisory Remote Equipment .......................................................................................... 31
F. Annunciator System............................................................................................................ 31

LIST OF TABLES

Table 1. Potential Faults that may cause High Wheelspace Temperature ..........................................................8
Table 2. Mode Select & Master Control Options ............................................................................................31
Table 3. Definitions & Terms..........................................................................................................................31

I. REFERENCE DATA AND PRECAUTIONS

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 6 of 32

GEK116689A Unit Operation - Turbine (Gas)

A. Operator Responsibility

It is essential that the turbine operators be familiar with the information contained in the following
operations documentation, the Control Specification drawings (Found in the O&M manual),
Operation Tab, the Piping Schematic drawings including the Device Summary (consult the Control
System Settings Drawing for the index by model list and drawing number of applicable schematics),
the Turbine Control Application Software control sequence program and the Controller System
Guide Users' Manual. The operator must also be aware of the power plant devices, which are tied into
the gas turbine mechanically and electrically and could affect normal operation.

No starts should be attempted whether on a new turbine or a newly overhauled turbine until the
following conditions have been met:

1. Requirements listed under CHECKS PRIOR TO OPERATION have been met.

2. Control systems have been functionally checked for proper operation before restarting.

3. All GENERAL OPERATING PRECAUTIONS have been noted.

It is extremely important that gas turbine operators establish proper operating practices. We
emphasize adherence to the following:

1. Respond to Annunciator /Alarm Indicators

Investigate and correct the cause of the abnormal condition. This is particularly true for the
protection systems such as low oil pressure, over temperature, vibration, overspeed etc.

2. Check of Control Systems

After any type of control maintenance is completed, whether repair or replacement of parts,
functionally check control systems for proper operation. This should be done prior to restart of
the turbine. It should not be assumed that reassembly, “as taken apart” is adequate without the
functional test.

3. Monitor Exhaust
Monitor exhaust temperature and exhaust temperature spreads during all phases of startup

B. Turbine Controller Unauthorized Access and Modifications

1. Unauthorized access and modifications, (e.g., forcing logic signals to customer gas turbine
controllers) can create hazardous conditions for personnel and equipment. Customers are advised
to implement physical or software access procedures to the gas turbine controllers to prevent
unauthorized access and subsequent possible hazardous conditions.

2. MARK*1VIe ToolboxST provides various ‘Access Rights.’ Reference GEH 6700, Chapter 1 for
details.

3. Privilege-level passwords are provided that allow the ability to force logic signals. It is intended
that logic forcing only be used for off-line software checkout procedures, while the unit is shut
down, and in conjunction with proper lockout / tag-out procedures.

1
*MARK is a registered trademark of General Electric Company

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 7 of 32

Unit Operation - Turbine (Gas) GEK116689A

NOTE

Customer personnel shall not force logic signals to circumvent control and
protection functions.

4. The customer is responsible for password-protecting privilege levels or access rights within the
Mark*VIe to limit access to control settings and logic forcing to qualified personnel only.

C. General Operating Precautions

1. Temperature Limits
Monitoring the exhaust temperature spread information is useful to understand the degradation
of hardware components over time. Sudden shifts in this spread pattern can also indicate
developing or actual hardware problems. It is important to define a “baseline value” of exhaust
temperature spread with which to compare future data. This baseline data is established during
steady state operation after each of the following conditions:

a. Initial startup of unit

b. Before and after a planned shut-down
c. Before and after planned maintenance
It is important, when evaluating the magnitude of the exhaust temperature spread, to consider
both the magnitude of the spread as well as the change of the spread over time. Consult the
Control Specification Drawing for further information on the maximum allowable temperature
spreads and wheelspace temperature operating limits.

The wheelspace thermocouples, identified together with their nomenclature, are listed in the
Device Summary. A bad thermocouple will cause a “High Wheelspace Differential
Temperature” alarm. The faulty thermocouple should be replaced at the earliest convenience.

Table 1 lists potential faults that cause high wheelspace temperature.

CAUTION

Wheelspace temperatures are read on the operators interface. Temperatures in excess of

alarm level values are potentially harmful to turbine hot-gas-path and rotor parts over a
prolonged period of time.
Excessive temperatures are annunciated but will not cause the turbine to trip. High
wheelspace temperature readings must be reported to the General Electric Company
technical representative as soon as possible.

1. Restriction in cooling air lines, most often cooling and sealing air valves left
improperly isolated after a water wash.
2. Wear of turbine seals
3. Excessive distortion of the turbine stator

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GEK116689A Unit Operation - Turbine (Gas)

4. Improper positioning of thermocouple

5. Malfunctioning combustion system
6. Leakage in external piping
7. Excessive distortion of exhaust inner diffuser

Table 1. Potential Faults that may cause High Wheelspace Temperature

Wheelspace temperatures should be very closely monitored on initial startup. If a check of the
external cooling air circuits reveals no explanation for consistently high temperatures, a General
Electric Company technical representative should be contacted as soon as possible.

If the turbine is overloaded to such an extent that turbine temperature control schedules are not
followed due to equipment malfunction or improper setting of the temperature control system,
the maximum allowable turbine inlet temperature and/or the maximum allowable exhaust
temperature will be exceeded. This will necessitate more frequent and/or more extensive
maintenance, and might result in failure of the turbine parts.

CAUTION

Over temperature can damage the turbine hot gas path parts.

2. Pressure Limits
Lube oil pressure in the bearing feed header is maintained by a mechanical pressure regulating
valve. A low-bearing header pressure alarm is generated if the pressure in the header drops
below the low limit. The turbine will trip if the pressure at the Generator #2 bearing drops below
the low-low limit. These limits are typically 25 and 8 psi respectively. Refer to the unit specific
control specification to verify actual values.

3. Vibration Limits

NOTE

The maximum overall vibration velocity of the gas turbine should never exceed 1.0
inch (2.54 cm) per second in either the vertical or horizontal direction.

Corrective action should be initiated when the vibration levels exceed 0.5 inch (1.27 cm) per
second as indicated on the control system HMI. This level of vibration will initiate an alarm.

4. Load Limit, Overloading of Gas Turbine, Facts Involved and Policy

The maximum load capability of the gas turbine is given in the control specification. For the
upper limits of generator capability, refer to the Reactive Capability Curve found in the
Generator Tab of the O&M manual

a. It is the General Electric Company practice to design gas turbines with margins of safety that
can meet the contract commitments and secure long life and trouble-free operation.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 9 of 32

Unit Operation - Turbine (Gas) GEK116689A

General Electric Company designs these machines with margins on turbine bucket thermal
and dynamic stresses, compressor and turbine wheel stresses, generator ventilation, coolers,
etc. in order to secure maximum trouble-free operation because of the importance of
reliability of these turbines to our customers and to the electrical generation industry.
CAUTION

It is not recommended to run these machines beyond the load limits. Such operation
always encroaches upon the design margins of the machines with a consequent reduction
in reliability and increased need for maintenance. Accordingly, any malfunction that
occurs as a result of operation beyond contract limits cannot be the responsibility of
General Electric Company.

b. AIEE Standards
Per the AIEE Standards, it is permitted to operate generators at temperature rises below
185°F (85°C) for the rotor and 140°F (60°C) for the stator; however this does not mean that
the generator can be properly run with full safety up to these values by overloading beyond
the nameplate rating.
These standards were primarily set up for the protection of insulation from thermal
deterioration on small machines. The imbedded temperature detectors of the stator register a
lower temperature than the copper windings because of the temperature drop through the
insulation from the copper to the outside of the insulation, where the temperature detectors
are located.
c. Variable Conditions
There are also conditions of conductor expansion, insulation stress, etc., which impose
limitations. These factors have been anticipated in the “Vee” curves and reactive capability
curves, which indicate recommended values consistent with good operating practice. The
“Vee” curves and reactive capability curves form part of the operating instructions for the
generator and it is considered unwise to exceed the values given.
d. Adhering to set limits
Gas turbines are mechanically designed so that (within proscribed limits), advantage can be
taken of the increased capability over nameplate rating, which is available at lower ambient
temperatures (because of increased air density), without exceeding the maximum allowable
turbine inlet temperature.
The load limit of the gas turbine-generator must not be exceeded, even when the ambient
temperature is lower than that at which the load limit of the gas turbine is reached. Under
these conditions, the gas turbine will operate at this load with a lower turbine inlet
temperature and the design stresses on the load coupling and turbine shaft will not be
exceeded.

5. Fire Protection System Operating Precautions

When the fire protection system is actuated, the media discharge system will actuate, as well as
the following:

a. The turbine will trip;

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GEK116689A Unit Operation - Turbine (Gas)

b. An audible alarm will sound;

c. The alarm message will be displayed on the HMI;
d. The ventilation openings in the compartments will be closed by a pressure-operated latch,
gravity, or both; and
e. All ventilation fans will shut down by electrical interlocks.
This audible alarm may be silenced by clicking on the alarm SILENCE target. The alarm
message can be cleared from the ALARM list on the HMI, after the ACKNOWLEDGE target
and the ALARM RESET target are actuated, but only after the situation causing the alarm has
been corrected.

The fire protection system must be recharged and reset before it can automatically react to
another fire. Reset must be made after each activation of the fire protection system, including an
initial discharge that is followed by an extended discharge period of the fire protection media.
Fire protection system reset is accomplished by resetting the pressure switch located on the fire
protection system.

Ventilation dampers, automatically closed by a signal received from the fire protection system,
must be reopened manually in all compartments before restarting the turbine.

CAUTION

Failure to reopen/relatch compartment ventilation dampers will severely shorten the

service life of major accessory equipment, due to compartment over temperature. Failure
to reopen the load-coupling compartment dampers will materially reduce the
performance of the generator.

6. Combustion System Operating Precautions

The gas turbine control implements many automatic protective features with respect to the
combustion system. These protection systems should be reviewed in order to understand what
they indicate about unit hardware as well as to ensure that the components of these systems are
maintained in proper functioning order. This will reduce distortions of the control and protection
functions and the number of unnecessary turbine trips.

a) Automatic protective functions

i. Exhaust Spread monitor

- Detect full or partial flameout and trip fuel system

- Indicate hardware deterioration or abnormal operation

ii. Combustion dynamics runback

- Exists on units equipped with Combustion Dynamics Monitoring (CDM) system from
approximately 2012

- Protect against hardware fatigue due to elevated dynamics

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Unit Operation - Turbine (Gas) GEK116689A

iii. DLN fuel nozzle fuses (DLN2.6 only)

The fuses are designed to melt if the flame re-positions into the burner tube. Once it is
melted, the gas flow path is altered such that flame in the burner tube can no longer be
sustained. This is intended to minimize hardware damage and potential collateral damage
to the turbine.

iv. Hazardous gas detection system

v. Detect potentially hazardous gas leakage, shutdown or trip fuel system

b) Operator protective expectations

i. Ensure that after any unit hardware change or significant fuel system work, the unit is
properly DLN tuned prior to standard operation.

ii. Monitor emissions, take action on abnormal emissions levels

iii. Monitoring combustion dynamics, take action at elevated levels

iv. Ensure accuracy of all control transmitters, take action on abnormal readings.

v. Ensure integrity of exhaust spread monitor (do not jumper exhaust thermocouples). Keep
the number of nonoperational exhaust thermocouples to a maximum of two but no more
than one of any three adjacent thermocouples.

vi. Ensure proper operation of startup or dew point fuel heaters - liquid carryover into the
gas fuel system often results in combustion component damage

vii. Ensure that gas system conditioning equipment is properly maintained and liquids
properly drained

viii. Liquid fuel drain system properly operating on dual fuel units

CAUTION

Operation of the gas turbine with a single faulty thermocouple should not be neglected,
as even one faulty thermocouple will increase the risk of an invalid “combustion alarm”
and/or “Trip”. The unit does not have to be shut down just for replacement of a single
faulty thermocouple. However, every effort should be made to replace the faulty
thermocouples when the machine is down for any reason.

CAUTION

If, during operation, there has been an increase in exhaust temperature spread above the
normal 65°F to 80°F (18.3°C to 26.6°C), the thermocouples in the exhaust plenum
should be examined. If they are coated with ash, the ash should be removed. Radiation
shields should also be checked.

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GEK116689A Unit Operation - Turbine (Gas)

If they are not radially oriented relative to the turbine, they should be repositioned per
the appropriate drawing. If the thermocouples are coated with ash, or if the radiation
shields are not properly oriented, a correct temperature reading will not be obtained.
If neither of the above conditions exists and there is no other explanation for the
temperature spread, consult General Electric Company Installation and Service
Engineering representative.

***WARNING***

OPERATING A TURBINE WITH NON-OPERATIONAL EXHAUST

THERMOCOUPLES INCREASES THE RISK OF TURBINE OVER-
FIRING AND PREVENTS DIAGNOSIS OF COMBUSTION PROBLEMS
BY USE OF TEMPERATURE DIFFERENTIAL READINGS.

7. Radio transmissions
The use of radio transmitting equipment in the vicinity of open control panels is not
recommended. Prohibiting such use will ensure that no extraneous signals are introduced into the
control system that might influence the normal operation of the equipment.

II. PREPARATIONS FOR NORMAL LOAD OPERATION

A. Standby Power Requirements

Standby AC power insures the immediate startup capability of particular turbine equipment and
related control systems when the start signal is given. Functions identified by asterisk* are also
necessary for unit environmental protection and should not be turned off, except for maintenance
work on that particular function / system.

Standby AC power is required for:

1. Lube oil heaters, which when used in conjunction with the lube oil pumps, heat and circulate
turbine lube oil at low ambient temperatures to maintain proper oil viscosity.

2. *Control panel heating.

3. *Generator heating.

4. Lube oil pumps. Auxiliary pump should be run at periodic intervals to prevent rust formation in
the lube oil system.

5. Fuel oil heaters, where used. These heaters used in conjunction with the fuel oil pumps, heat and
circulate fuel oil at low ambient temperatures to maintain proper fuel oil viscosity.

6. *Compartment heating (Humidity/Freeze Protection).

7. *Operation of control compartment air conditioner during periods of high ambient temperature
to maintain electrical equipment within design temperature limits.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 13 of 32

Unit Operation - Turbine (Gas) GEK116689A

8. *Battery charging

9. *H2 Monitor.

10. Seal Oil Pumps

11. Hazardous Gas Monitoring

B. Checks Prior to Operation

The following checks are to be made before attempting to operate a new turbine or an overhauled
turbine. It is assumed that the turbine has been assembled correctly, is in alignment and that
calibration of the Turbine Control System has been performed per the Control Specifications. A
standby inspection of the turbine should be performed with the lube oil pump operating and emphasis
on the following areas:

1. Check that all piping and turbine connections are securely fastened and that all blinds have been
removed. Most tube fittings incorporate a stop collar, which insures proper torqueing of the
fittings at initial fitting make up and at reassembly.

2. Inlet and exhaust plenums and associated ducting are clean and rid of all foreign objects. All
access doors are secure. Reference GEK111332 for further Operation and Maintenance
Recommendations.

3. Inlet filter house integrity should be verified to ensure correct installation and proper sealing to
minimize the risk of unfiltered air and/or water entering the gas turbine. Reference GEK111330
for further Operation and Maintenance Recommendations.

4. Where fuel, air or lube oil filters have been replaced check that all covers are intact and tight.

5. Verify that the lube oil tank is within the operating level and if the tank has been drained that it
has been refilled with the recommended quality and quantity of lube oil. If lube oil flushing has
been conducted verify that all filters have been replaced and any blinds if used, removed.

6. Check operation of auxiliary and emergency equipment, such as lube oil pumps, water pumps,
fuel forwarding pumps, etc. Check for obvious leakage, abnormal vibration (maximum 3 mils),
noise or overheating.

7. Check lube oil piping for obvious leakage. Also using provided oil flow sights, check visually
that oil is flowing from the bearing drains. The turbine should not be started unless flow is
visible at each flow sight.

8. Check condition of all thermocouples and/or resistance temperature detectors (RTDs) on the
HMI. Reading should be approximately ambient temperature.

9. Check spark plugs for proper arcing, refer to Combustion I&M manual, prior to final installation
to avoid wasting gasket materials.

If the arc occurs anywhere other than directly across the gap at the tips of the electrodes, or if by
blowing on the arc it can be moved from this point, the plug should be cleaned and the tip
clearance adjusted. If necessary, the plug should be replaced. Check the retracting piston for free
operation.
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GEK116689A Unit Operation - Turbine (Gas)

***WARNING***

DO NOT TEST SPARK PLUGS WHERE

EXPLOSIVE ATMOSPHERE IS PRESENT.

10. Check all HMI Alarm and Diagnostics.

11. Devices requiring manual lubrication are to be properly serviced.

12. Determine that the cooling water system has been properly flushed and filled with the
recommended coolant.

a. Any fine powdery rust, which might form in the piping during a short period of exposure to
atmosphere, can be tolerated.

b. If there is evidence of scaly rust, the cooling system should be power flushed until all scale is
removed.

c. If it is necessary to use a chemical cleaner, most automobile cooling system cleaners are
acceptable and will not damage the carbon and rubber parts of the pump mechanical seals or
rubber parts in the piping.

Refer to “Cooling Water Recommendations for Combustion Gas Turbine Closed Cooling
Systems” included under tab titled Fluid Specifications. Note the following regarding
antifreeze.

CAUTION

Do not change type of antifreeze without first flushing the cooling system very
thoroughly. Inhibitors used may not be compatible and can cause formation of gums, in
addition to destroying effectiveness as an inhibitor. Consult the antifreeze vendor for
specific recommendations

Maintaining the water system refill ensures that the water system piping, primarily pumps
and flexible couplings, do not leak. It is wise not to add any corrosion inhibitors until after
the water system is found to be leak free.

Water Leaks and abnormal flow rates can compromise the operability of the cooling water
system and can pose a significant hazard to the compressor rotor and stator components when
leaks are in the turbine compartment. This applies not only to the cooling water system but to
the water wash system and where applicable the water injection systems also.

The following inspections should be performed:

1) Verify that piping and tubing are properly supported and that there is no rubbing or
abrading in any way.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 15 of 32

Unit Operation - Turbine (Gas) GEK116689A

2) Check for any damage, wear, loose fittings, interference, fretting, or anything else that
may lead to leaks or system malfunctions.
For the flame detector cooling water piping, ensure that the high-point vent cap is in place
and properly installed, in particular after the system has been vented. When inspecting the
flame detector cooling coils ensure that the clamp is not in contact with the cooling tubes.
Verify that the flame detector cooling coils are tight, with no relative motion between the
clamp and cooling coil. Visually inspect for wear on the flame scanner cooling coils. If any
wear is noted the cooling coil should be replaced immediately in order to avoid potential
coolant leaks.

Closely monitor the water level in expansion tanks. Any significant drops in the water level
will indicate a leak in the cooling water system. When inspecting the water wash aft
manifold, ensure the water wash nozzle fittings are installed and properly tightened. Visually
inspect for damage to the tubing and fittings.

When inspecting the water injection system on base piping and manifold, ensure the flow
proportioning valves or check valves are installed properly on the tubing or flex hoses
connecting the manifold to the end cover. Visually inspect all tubing and flex hoses for
damage at weld points and check valve and end-cover connection points.

13. The Load Commutator Inverter (LCI) should be calibrated and tested per GEH-6192.

14. Check the Cooling and Sealing Air Piping against the assembly drawing and piping schematic, to
ensure that all orifice plates are of designated size and in designated positions.

15. At this time all annunciated ground faults should be cleared. It is recommended that units not be
operated when a ground fault is indicated. Immediate action should be taken to locate all grounds
and correct the problems.

C. Checks during Start Up and Initial Operation

The following is a list of important checks to be made on a new or newly overhauled turbine with the
OPERATION SELECTOR switch in various modes. The Control Specifications drawing should be
reviewed prior to operating the turbine.

When a unit has been overhauled those parts or components that have been removed and taken apart
for inspection/repair should be critically monitored during unit startup and operation. This inspection
should include: leakage check, vibration, unusual noise, overheating, and lubrication.

1. Crank Mode
a. Listen for rubbing noises in the turbine compartment, especially in the load tunnel area. A
sound-scope or some other listening type device is suggested. Shut down and investigate if
unusual noise occurs.
b. Check for unusual vibration.
c. Inspect for water system leakage.

***WARNING***

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GEK116689A Unit Operation - Turbine (Gas)

KEEP COMPARTMENT DOORS CLOSED AT ALL TIMES DURING

ENGINE OPERATION, ENGINE STARTUP AND SHUTDOWN, AS
WELL AS ENGINE COOL DOWN PERIODS.

2. Fire Mode
Fire mode is to be used for initial commissioning, or following a major outage for the purpose of
re-commissioning.

a. Turbine Compartment
Check the entire fuel system and the area immediately around the fuel nozzle for leaks. In
particular check for leaks at the following points:
1) Fuel piping/tubing to fuel nozzles
2) Fuel check valves (when used)
3) Atomizing air manifold and associated piping (when used)
4) Gas manifold and associated piping
b. Liquid Fuel Module (when used)
1) Bleed fuel oil filters, if appropriate, to remove trapped air.
2) Flow divider
3) Fuel and water pumps
4) Filter covers and drains
5) Bulk head Floor Swagelock connections
c. Monitor FLAME status on the HMI processor to verify all flame detectors are correctly
indicating flame.
d. Monitor the turbine control system readings on the HMI processor for unusual exhaust
thermocouple temperature, wheelspace temperature, lube oil drain temperature, highest to
lowest exhaust temperature spreads and “hot spots” i.e. combustion chamber(s) burning
hotter than all the others.
e. Listen for unusual noises and rubbing.
f. Monitor for excessive vibration.

CAUTION

Elimination of fuel leakage in the turbine compartment is of extreme importance as a

fire preventive measure.

***WARNING***

DUE TO THE COMPLEXITY OF GAS TURBINE FUEL SYSTEMS, IT

IS IMPERATIVE FOR PLANT PERSONNEL TO EXERCISE EXTREME

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 17 of 32

Unit Operation - Turbine (Gas) GEK116689A

CAUTION IN AND NEAR ANY TURBINE COMPARTMENT, FUEL

HANDLING SYSTEM, OR ANY OTHER ENCLOSURES OR AREAS
CONTAINING FUEL PIPING OR FUEL SYSTEM COMPONENTS.
DO NOT ENTER THE TURBINE COMPARTMENT UNLESS
ABSOLUTELY NECESSARY.
IF IT IS NECESSARY TO ENTER THE COMPARTMENT, EXERCISE
EXTREME CAUTION WHEN OPENING AND ENTERING THE
COMPARTMENT. BE AWARE OF THE POSSIBILITY OF FUEL
LEAKS, AND BE PREPARED TO SHUT DOWN THE TURBINE AND
TAKE ACTION IF A LEAK IS DISCOVERED.
AT ANY TIME, IF/WHEN ENTERING THE TURBINE
COMPARTMENT OR WHEN IN THE VICINITY OF THE FUEL
HANDLING SYSTEM OR OTHER LOCATIONS WITH FUEL PIPING,
FUEL SYSTEM COMPONENTS OR FUEL SYSTEM CONNECTIONS,
TAKE THE FOLLOWING STEPS:
1. Conduct an environmental evaluation of the turbine compartment, fuel
handling system, or other area with particular attention to all locations
where fuel piping, connections, components exist.
2. Follow applicable procedures for leak testing if fuel leaks are discovered,
exit the area quickly. Shut the turbine down and take appropriate actions
to eliminate all leaks.
3. Require personnel entering the turbine compartment to be fitted with
appropriate personal protective equipment, such as
a. hardhats,
b. safety glasses,
c. safety protection,
d. harness/manline (optional, depending on space constraints),
e. heat resistant & flame retardant coveralls, and
f. gloves.
4. Designate an attendant to maintain visual contact with personnel inside
the turbine compartment, and radio communication with the control
room operator.

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GEK116689A Unit Operation - Turbine (Gas)

***WARNING***

DURING THE FIRST START-UP AFTER A DISASSEMBLY, VISUALLY

CHECK ALL CONNECTIONS FOR FUEL LEAKS.
PREFERABLY CHECK THE FITTINGS DURING THE WARM-UP
PERIOD WHEN PRESSURES ARE LOW.
VISUALLY INSPECT THE FITTINGS AGAIN AT FULL SPEED, NO
LOAD, AND AT FULL LOAD.
DO NOT ATTEMPT TO CORRECT LEAKAGE PROBLEMS BY
TIGHTENING FITTINGS AND/OR BOLTING WHILE LINES ARE
FULLY PRESSURIZED.
NOTE THE AFFECTED AREA AND, DEPENDING ON THE SEVERITY
OF LEAK(S), REPAIR AT NEXT SHUTDOWN, OR IF IMMEDIATE
REPAIR IS REQUIRED, SHUT UNIT DOWN IMMEDIATELY.
ATTEMPTS TO CORRECT LEAKAGE PROBLEM ON PRESSURIZED
LINES COULD LEAD TO SUDDEN AND COMPLETE FAILURE OF
COMPONENT AND RESULTING DAMAGE TO EQUIPMENT AND
PERSONNEL INJURY.

3. Automatic
On initial startup of a new unit, if the unit has not been run through the GE Full Speed No Load
(FSNL) Factory Test, the green rotor run-in procedure found under MLI 0234 must be adhered
to. If the unit was run in the factory these structural checks have already been performed and
standard installation procedures apply.

a. For all startups turbine and generator vibration monitoring is required using the units
proximity probes and velocity seismic sensors.
b. Check wheelspace, exhaust and control thermocouples for proper indication on the HMI.
Record these values for future reference.
c. Utilize all planned shutdowns in testing the Electronic Trip System per the Control
Specifications drawing.
d. Monitor HMI display data for proper operation.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 19 of 32

Unit Operation - Turbine (Gas) GEK116689A

III. OPERATING PROCEDURES

A. General
The following instructions pertain to the operation of a gas turbine unit designed for generator drive
application. These instructions are based on use of Mark* VIe turbine control panels.
Functional description of the HMI Main Startup Display follows; however, panel installation,
calibration, and maintenance are not included.
As described below, the procedure assumes that the turbine is in the cool down or standby mode
ready for normal operation with AC and DC power available for all pumps, motors, heaters, and
controls and all annunciator drops are cleared.

B. Start-Up

1. General
Startup of a single turbine/generator unit may be accomplished either locally or remotely.

To transfer turbine control from the control compartment to remotely located equipment, select
REMOTE on the HMI Main Startup Display. The turbine may then be started, automatically
synchronized, and loaded by the remote equipment.

The following description lists operator, control system and machine actions or events in starting
the gas turbine. Reference the section “Description of Panels and Terms-Turbine Control Panel"
for description of turbine panel devices. The following assumes that the unit is in a ready to start
condition.

2. Starting Procedure
a. The display will indicate speed, temperature, various conditions etc. Three lines displayed on
the HMI will read:
SHUTDOWN
ON COOL DOWN
OFF

b. Select “AUTO” and confirm the selection. The HMI display will change to:
STARTUP
READY TO START
AUTO

c. Select “START” and confirm the selection.

1) Unit auxiliaries will be started including a motor driven lube oil pump used to establish
lube oil pressure. During this period, a test of the emergency lube oil pump is completed.
If this test fails the start will be inhibited.
2) When all permissives are satisfied, the master protective logic (L4) will be satisfied. The
HMI display will change to:
STARTUP
STARTING
AUTO

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3) The turbine shaft will begin to rotate on turning gear. The zero speed signal “14HR” will
be displayed. When the unit reaches approximately 6 rpm, the starting device will be
energized and accelerate the unit. The HMI display will change to: CRANKING.
4) When the unit reaches approximately 14% speed, the minimum speed signal “14HM”
will be displayed on the HMI.
5) The starting device will crank the gas turbine at purge speed for a period of time
determined by the setting of the purge timer. See Control Specifications-Settings
Drawing for purge timer settings.
6) FSR will be set to firing value. (FSR, Fuel Stroke Reference, is the electrical signal that
determines the amount of fuel delivered to the turbine combustion system.) Ignition
sequence is initiated. The HMI display will change to FIRING.
7) When flame is established, the HMI display will indicate flame based on the status of the
flame detectors.
8) FSR will transition to warm-up value, and the HMI display will indicate WARMING
UP. If the turbine fails to ignite on gas fuel, the unit returns to purge speed for an auto re-
purge cycle.
After the auto re-purge cycle is complete the turbine holds at firing speed until the
operator selects STOP or START from the operator interface. A STOP selection initiates
a normal shutdown and a START selection initiates a second attempt to ignite. If a
failure to ignite occurs a second time the turbine returns to purge speed and completes
auto re-purge cycle followed by a turbine trip.
9) At the end of the warm-up period, with flame established, FSR will begin increasing. The
HMI will indicate ACCELERATING and the turbine will increase in speed. At
approximately 50% speed, the accelerating speed signal “14HA” will be displayed on the
HMI.
10) The turbine will continue to accelerate. When it reaches 91% speed, the starting device
will disengage.
11) When the turbine reaches operating speed (95%), the operating speed signal “14HS” will
be displayed on the HMI. Generator field flashing is initiated. If the synchronizing is not
selected on the HMI, as the turbine reaches operating speed, HMI display will change to:
RUNNING
FULL SPEED NO LOAD
AUTO
12) If Auto-Synch is selected on the HMI automatic synchronizing is initiated. The HMI will
read SYNCHRONIZING.
13) The turbine speed is matched to the system and when the proper phase relationship is
achieved the generator breaker will close. The machine will load to Spinning Reserve
unless a load control point BASE, PEAK or PRESELECTED LOAD has been selected.
14) The HMI will display SPINNING RESERVE, once the unit has reached this load point.

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Unit Operation - Turbine (Gas) GEK116689A

C. Synchronizing

When a gas turbine-driven synchronous generator is connected into a power transmission system, the
phase angle of the generator going on-line must correspond to the phase angle of the existing line
voltage at the moment of its introduction into the system. This is called synchronizing.
CAUTION

Before initiating synchronization procedures, be sure that all synchronization equipment

is functioning properly, and that the phase sequence of the incoming unit corresponds to
the existing line phase sequence and the potential transformers are connected correctly
to proper phases. Initial synchronization and checkout after performing maintenance to
synchronizing equipment should be performed with the breaker racked out.

NOTE

Only one lube oil & hydraulic motor (and no seal oil motor) is allowed to be
running for synchronization.

1. Manual Synchronization
a. Select AUTO on the HMI Main Startup Display.
b. Select START and Confirm the selection on the HMI Main Startup Display. This will start
the turbine and accelerate it to full speed as previously described. At this point the HMI will
indicate RUN STATUS, FULL SPEED NO LOAD.
c. Select 'MAN SYNCH' on the HMI Synchronization Display.
d. Compare the generator voltage with the line voltage. (These values are located on the HMI
Synchronization display.)
e. Make any necessary voltage adjustment by operating the RAISE- LOWER buttons on the
HMI display until the generator voltage equals the line voltage.
f. Compare the generator and line frequency on the synchroscope (located on the
Synchronization HMI display). If the pointer is rotating counterclockwise, the generator
frequency is lower than the line frequency and should be raised by increasing the
turbine/generator speed.
g. Adjust the speed until the synchroscope rotates clockwise at approximately five seconds per
revolution or slower.
h. The generator circuit breaker "close" signal should be given when it reaches a point
approximately one minute before the 12 o'clock position. This allows for a time lag for the
breaker contacts to close after receiving the close signal.

2. Automatic Synchronization
a. Select AUTO on the HMI Main Display.
b. Select START and Confirm the selection on the HMI Main Startup Display. This will start
the turbine and accelerate it to full speed as previously described. At this point the HMI will
indicate RUN STATUS, FULL SPEED NO LOAD.
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GEK116689A Unit Operation - Turbine (Gas)

c. Select 'AUTO SYNCH' on the HMI Synchronization display.

d. The control system will match generator voltage to line voltage, synchronize the generator to
the line frequency, and load the generator to the spinning reserve value.
e. If a synch fails for any reason, it may be necessary to either select START on the HMI Main
Startup Display or select RE-SYNC on the HMI synchronization display to reset the
sequence.
Once the generator has been connected to the power system, the turbine fuel flow may be
increased to pick up load, and the generator excitation may be adjusted to obtain the desired kvar
value.

***WARNING***

FAILURE TO SYNCHRONIZE PROPERLY MAY RESULT IN

EQUIPMENT DAMAGE AND/OR FAILURE, OR THE CREATION OF
CIRCUMSTANCES WHICH COULD RESULT IN THE AUTOMATIC
REMOVAL OF GENERATING CAPACITY FROM THE POWER
SYSTEM.

In those cases where out-of-phase breaker closures are not serious enough to cause immediate
equipment failure or system disruption, cumulative damage may result to the on-coming
generator. Repeated occurrences of out-of-phase breaker closures can eventually result in
generator failure because of the stresses created at the time of closure.

Out-of-phase breaker closure of a magnitude sufficient to cause either immediate or cumulative

equipment damage mentioned above will usually result in annunciator drops to notify the
operator of the problem. The following alarms have been displayed at various occurrences of
known generator breaker mal-closures:

a. High vibration trip

b. Loss of excitation
c. Various AC under voltage drops
Out-of-phase breaker closure will result in abnormal generator noise and vibration at the time of
closure. If there is reason to suspect such breaker mal-closure, the equipment should be
immediately inspected to determine the cause of the mal-closure and for any damage to the
generator.

D. Normal Load Operation

1. Manual Loading
Manual loading is accomplished by clicking on the SPEED/LOAD RAISE/LOWER targets on
the HMI Main Startup Display.

Manual loading beyond the selected temperature control point BASE or PEAK (if applicable) is
not possible. The manual loading rate is shown in the Control Specification-Settings Drawing.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 23 of 32

Unit Operation - Turbine (Gas) GEK116689A

2. Automatic Loading
On startup if no load point is selected, the unit will load to the SPINNING RESERVE load point.
The SPINNING RESERVE load point is slightly greater than no load, typically 5-10% of base
rating.

An intermediate load point, PRE-SELECTED load or External Load setpoint, and temperature
control load points BASE or PEAK (if applicable) can be selected any time after a start signal
has been given. The selection will be displayed on the HMI. The unit will load to the selected
load point. PRESELECTED LOAD is a load point greater than SPINNING RESERVE and less
than BASE or the PEAK LIMIT (if applicable) if selected. The auto-loading rate is shown in
Control Specification-Settings Drawing typically 8.3% rated output/minute. Note that this is
rated output. Control Specification setting is % of load set point.

E. DLN System Operation

1. General
Dry Low NOx control systems regulate the distribution of fuel delivered to multi-nozzle
combustors located around the gas turbine. These systems stage the fuel through multiple modes
of operation to attain low emissions at base load.

2. Gas Fuel Operation

Each DLN combustion system operates in a series of modes to achieve desired operation at
various loads. This is done with multiple control valves. See the following GEKs for more
information on mode sequences and valve configurations:

a. GEK116359 Dry Low NOx 2.0+ System Operation

b. GEK116480 Fuel Gas Control System (DLN 2.6)
c. GEK116263 Gas Fuel System - DLN 2.6+

3. Inlet Guide Vane Operation (IGV)

a. DLN combustion systems are sensitive to changes in fuel to air ratio. DLN combustors are
designed according to the airflow regulation scheme used with IGV Temperature Control.
b. As the gas turbine is loaded, the IGVs should remain at a fixed minimum value from full
speed no load until the gas turbine exhaust temperature increases to the isotherm limit.
c. At this point, the IGVs will begin to open to maintain the appropriate temperature control
boundary, until they reach their maximum open limit.
d. If equipped, the Variable Stator Vanes (VSV) work in conjunction with the IGVs to control
airflow through the gas turbine compressor. The reference to the VSV actuator is a function
of IGV angle and Gas Turbine Corrected Speed.

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GEK116689A Unit Operation - Turbine (Gas)

4. Inlet Bleed Heat

Inlet heating via compressor bleed typically provides three primary functions:

a. Serve as compressor protection by increasing flow and decreasing pressure when required
b. Heat the inlet and front of compressor to prevent ice formation due to increased pressure drop
across the reduced IGV angle.
c. Prevent compressor airflow from entering the combustor, maintaining a favorable
temperature for premix operation

F. Shutdown, Cool down and Restart

1. Normal Shutdown
Normal shutdown is initiated by selecting STOP on the HMI Main Startup Display. The control
system will follow automatically through generator unloading, generator breaker opening,
turbine speed reduction, fuel shutoff at part speed and initiation of the cool down sequence.

2. Emergency Shutdown
Emergency shutdown is initiated by depressing the EMERGENCY STOP pushbutton, located on
the turbine control panel or remotely located at the operator station.. The EMERGENCY STOP
button will disable the turning gear and cool down sequence. Unless this is intended, the button
should be released (unlatched) during coast down.

CAUTION

In the event of an emergency shutdown in which internal damage of any rotating

equipment is suspected, do not turn the rotor after shutdown. Maintain lube oil pump
operation, since lack of circulating lube oil following a hot shutdown will result in rising
bearing temperatures which can result in damaged bearing surfaces. If the malfunction
that caused the shutdown can be quickly repaired, or if a check reveals no internal
damage affecting the rotating parts, recommence the cool down cycle.

3. Cool down
The HMI Main Startup Display contains COOL DOWN CONTROL. Upon unit shutdown, either
normal or emergency, the unit will automatically select cool down control ON. Cool down
control will maintain the unit operating on turning gear with the lube oil and hydraulic pumps
running; however, cool down control cannot be selected OFF for a minimum of 24 hours from
shutdown. Selecting cool down control OFF will disable the turning gear. Once the unit reaches
ZERO speed, the hydraulic and lube oil pumps will be de-energized and the seal oil pump will
enable for units with hydrogen filled generators.

Proper cool down operation of the gas turbine is critical for the following reasons:

a. To avoid high vibrations on unit restart;

b. To control the unit clearances to avoid a compressor or turbine rub that would reduce overall
unit performance.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 25 of 32

Unit Operation - Turbine (Gas) GEK116689A

c. Control the rotor stresses to achieve maximum rotor life.

The standard cool down practice after a normal fired shutdown or unit trip from any load should
be rotation by unit turning gear until all turbine wheelspace temperatures are < 150 °F as
measured while unit at turning gear speed. At this condition the unit can be removed from
turning gear by selecting cool down control OFF. GER 3620 indicates the recommend turning
gear practices when the unit is left idle prior to startup and for extended durations.

If required, the cool down cycle may be accelerated using the starting device; in which case it
will be operated at cranking speed. The same 150 °F requirement for removal of all rotation
applies, but note that this temperate is to be measured and verified while the unit is at turning
gear speed, not at cranking condition.

CAUTION

Opening up the turbine compartment doors or the lagging panels should not be done as a
means to accelerate cool down period. The compartment is engineered to provide
specific cooling paths around the turbine to ensure uniform cooling. Disrupting this
cooling path will result in uneven cooling of the outer casings resulting in excessive
stress and uneven clearances.

4. Guidelines for Idle Rotor with Hot Unit

If there is a normal fired shutdown or trip, and the rotor achieves an idle state with no rotation
when the wheel space temperatures are > 150 °F then following guidelines apply:

a. If turning, cranking, or unit re-start is established in 20 minutes or less from a rotor idle
condition, no rotor bowing is presumed to have occurred and no additional operational
requirements are necessary.
b. If turning, cranking, or unit re-start cannot be established in 20 minutes or less from a rotor
idle condition then it is presumed that rotor bowing has occurred. The below bowed rotor
startup procedure requirements should be followed.
c. Bowed Rotor startup procedure
1) Bump check the unit rotor to ensure that it spins freely and to listen for any signs of rubs.
If free spinning operation cannot be achieved or if rubs are detected return the rotor to
idle and contact a GE technical service advisor for further instruction.
2) If the rotor freely spins and no rubs are detected, establish normal turning gear operation.
3) Maintain turning gear operation for a minimum of 8 hours
4) During subsequent start, monitor vibration and proximity sensors while the unit is at
purge condition. If seismic vibration readings are greater than 0.1 in/sec for either GT
bearing or proximity readings are above 0.8 mil, the start should be aborted.
5) If readings exceed above level and start is aborted, continue rotation on crank or turning
gear. Note that in this condition the unit should be cooled until wheel spaces are below
150 °F as noted above before brought to idle or re-start is attempted.

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GEK116689A Unit Operation - Turbine (Gas)

CAUTION

If, during turning operation, the gas turbine rotor seizes, the turbine should be shut down
and remain idle for at least 30 hours, or until the rotor is free. The turbine may be rotated
at any time during the 30-hour period if it is free; however, audible checks should be
made for rubs.

5. Unit Re-Start

NOTE

The following guidelines apply for normal unit operation. Initial commissioning of
a new unit or new rotor requires adherence to a rotor start or "green" rotor run-in
procedure. See addition details in Section II.C.3

When the gas turbine is hot, cranking and purging operation result in forced cooling
of the turbine components. Forced cooling has an adverse impact on the unit
clearances due to the differential cooling rates of the casing and rotor. While re-
starting the unit from an intermediately cooled condition is not restricted, it is
recommend that force cooling be allowed to proceed until wheel space temperatures
are <=225 Deg F as measured on turning gear prior to re-starting the unit.

G. Special Operations

1. Fuel Transfer (Gas-Distillate Option)

Fuel transfer is initiated using the Fuel Selection Buttons on the Main Startup Display of the
HMI. When transferring from one fuel to the other, there is a delay before the transfer begins
called the pre-fill time. Units with liquid fuel re-circulations systems will have a short pre-fill.
For the gas-to-distillate transfer, the delay allows for filling the liquid fuel lines. For the
distillate-to-gas transfer, the delay allows time for the speed ratio valve (and gas control valve) to
modulate the inter volume gas pressure before the transfer begins. Once started, fuel transfer
takes approximately thirty seconds.

2. Automatic Fuel Transfer On Low Gas Pressure (Gas-Distillate Option)

In the event of low fuel gas pressure the turbine will attempt to transfer to liquid fuel. The
transfer will occur with no delay for line filling. The success of a liquid fuel transfer depends on
the operating conditions of the liquid fuel system. To return to gas fuel operation after an
automatic transfer, manually reselect gas fuel.

Note that for units with "sliding P2" software the unit will first attempt to unload and remain on
gas operation prior to initiating a transfer to liquid fuel.

3. Testing the Emergency DC Lube Pump

The DC emergency pump may be tested using the test pushbutton on the motor starter.

4. Annual Trip Test ( previous overspeed Test)

GE has removed the annual requirement to operate and trip the unit at 110% speed for all multi-
shaft Heavy Duty Gas Turbines that utilize a MKV, MKVE, MKVI or MKVIe electronic

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 27 of 32

Unit Operation - Turbine (Gas) GEK116689A

overspeed trip circuit. GE still maintains an annual recommendation to perform a test of the
MKV, MKVe, MKVI or MKVIe trip circuits themselves. This test is performed though the Fired
Shutdown Trip Test.
a) Testing Requirements for the Fired Shutdown Trip Test:
The Fired Shutdown Trip Test should be performed on an annual basis or on the first
shutdown opportunity if the unit is continuously operated for greater then a year.

NOTE

Maintenance that calls into doubt any portion of the Trip Protection System should
be tested, at the earliest possible convenience after the outage in which the
modifications took place.
CAUTION

Under no circumstance may a test be run to test the emergency overspeed.

(Intentionally failing the first line of defense to test the second line)
The unit should never be run if either of the two lines of defense is known to be
nonoperational.

b) Fired Shut Down Trip Test Procedure

i. From the Overspeed Test Display, operator initiates Fired Shutdown (Stop button).

ii. Unit starts to shut down.

iii. Operator then initiates Fired Shutdown OST- Start button. (Speed less than 94%, in fired
shutdown, flame detected).

iv. Before flameout (50% speed), the controller auto changes the OS trip set point from
110% to 55% at which time the unit trips on over-speed.

v. System automatically checks the following during any OS trip event and will alarm if the
results are not as expected:

All Emergency Trip Relays (ETRs)/Primary Trip Relays (PTRs) confirmed open
Trip Header de-pressurized (for units with Hydraulic valves)
All valves closed

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GEK116689A Unit Operation - Turbine (Gas)

5. Temperature Matching
Temperature matching is used when the gas turbine exhaust temperature is to be controlled to
bring on a steam turbine. From the Temperature Matching Control Screen, the operator must
select temperature matching "ON."

Once selected, the turbine has to be loaded/unloaded to the matching window. Once the unit is in
the matching window, temperature matching begins. The gas turbine typically receives a
temperature matching reference from either the plant or steam turbine controller.

The gas turbine will control the exhaust temperature to the reference by modulating the IGVs.
The IGVs will open to reduce the exhaust temperature and close to increase the exhaust
temperature. If the reference is higher than the exhaust temperature and the IGVs are at their
minimum position, the gas turbine will increase load to meet the reference.

6. Water Washing System Operation

a) General
Off-line Water washing should be scheduled during a normal shutdown, if possible.
This will allow enough time for the internal machine temperature to drop to the
required levels for the washing. Maintaining the unit at crank speed can shorten the
time required to cool the machine. During this cooling of the turbine, the wash
water is to be heated to the proper level.
The period between off-line water washes can be extended via frequent on-line
washing. When the compressor is suspected of being heavily fouled, an off-line
wash should be performed. The on-line compressor wash system allows an operator
to water wash the turbine compressor without having to shut down the turbine.
For off-line water wash, even with the water inlet temperatures within the GE
recommended parameters, see the current revision of TIL 1236 “Water Wash
Recommendations” and GEK116599 for updated turbine wheelspace temperature
limits. Contact your local General Electric Company representative for assistance or
for additional information.

b) Mandatory Precautions for Off-Line Water Wash

NOTE

Before water washing the compressor, inspect the inlet plenum and gas turbine
bellmouth for large accumulations of atmospheric contaminants, which could be
washed into the compressor. These deposits can be removed by washing with a
garden hose.
Before off-line water washing of the compressor the turbine blading temperature must be low
enough so that the water does not cause thermal shock.
To reduce this difference, the wash water may be heated and the turbine kept on crank until
the wheel space temperatures drop to an acceptable level. The wheel space temperatures are
read in the control room on the HMI.

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DWG Number GEK116689 Rev A Released 11/24/2014 Page 29 of 32

Unit Operation - Turbine (Gas) GEK116689A

CAUTION

The differential temperature between the wash water and the inter-stage wheel space
temperature must not be greater than 120°F (48.9°C) to prevent thermal shock to the hot
gas parts. The maximum wheel space temperature must be no greater than 150°F
(65.5°C) or Compressor inlet temperature (CTIM) + 70 °F as measured by the digital
thermocouple readout system on the turbine control panel.

***WARNING***

THE WATER WASH OPERATION INVOLVES WATER UNDER HIGH

PRESSURE.
CAUTION MUST BE EXERCISED TO ENSURE THE PROPER
POSITIONING OF ALL VALVES DURING THIS OPERATION.
SINCE THE WATER MAY ALSO BE HOT, NECESSARY
PRECAUTIONS SHOULD BE TAKEN IN HANDLING VALVES, PIPES,
AND POTENTIALLY HOT SURFACES.

c) Compressor Water Washing Methods

For methods of Compressor Washing, water quality specifications and further
recommendations refer to F Class Gas Turbine Compressor Washing GEKs in Unit Service
Manual.

7. Unit Operation After Failure to Fire on Liquid Fuel

After every failure to fire on oil, an automatic unit TRIP will be issued. This trip will hold true
until the unit has been below 2% speed for 2 minutes.

Once this trip condition is cleared a re-start command can be issued (provided other startup
permissives are met). This operation allows excess liquid fuel to drain from liners.

IV. DESCRIPTION OF PANELS AND TERMS

A. Turbine Control Panel (TCP)

The turbine control panel contains the hardware and software required to operate the turbine. A front
elevation view of the panel can be seen in the Hardware Description of the applicable GEH.

B. EMERGENCY STOP (5E)

This red pushbutton is located on the front of the TCP. Operation of this pushbutton immediately
shuts off turbine fuel and locks out the turning gear mechanism. The turbine will come to a complete
stop if left depressed.

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GEK116689A Unit Operation - Turbine (Gas)

C. HMI

The HMI is a personal computer that directly interfaces to the turbine control panel. This is the
primary operator station. All operator commands can be issued from the HMI. Alarm management
can be performed and turbine parameters can be monitored. With the proper password, turbine
software editing can also be accomplished.

All Mode Select, Master Control and Auxiliary Control selections are the SELECT/CONFIRM type,
which means that the target must first be selected and then also confirmed in order to actuate that
command.

1. Main Startup Display

Mode Select, Master Control and Auxiliary Control selections can be made from the startup
display by using the cursor-positioning device (CPD). Mode Select Options and Master Control
Options are detailed in Table 2.

MODE SELECT OPTIONS

OFF Inhibits a start signal.
CRANK With crank selected, a start signal will bring the machine to crank speed.
FIRE With FIRE selected, a START signal will bring the machine to minimum speed
and establish flame in the combustors. Selecting FIRE while the machine is on
CRANK will initiate the firing sequence and establish flame in the combustors if
the purge permissive has been met.
AUTO With AUTO selected, a START signal will bring the machine to operating speed.
Changing selections from FIRE to AUTO will allow the machine to accelerate to
operating speed.
REMOTE With REMOTE selected, control for the unit is transferred to the remote control
equipment.

MASTER CONTROL OPTIONS

START A START selection will cause the unit to start. With AUTO selected, the unit will
load to FULL SPEED NO LOAD.
STOP A STOP selection will cause the unit to initiate a normal shutdown. If the unit
generator breaker is closed, the unit will unload at the standard rate, automatically
open the breaker and continue to decelerate to a flameout and cool down condition

AUXILIARY CONTROL OPTIONS (INCLUDING)

COOL DOWN ON/OFF Cool down ON & OFF selection is used to put the turbine on turning gear speed
or stop the turbine from rotating for possible maintenance activities.

LOAD CONTROL SELECTIONS (MADE FROM STARTUP)

PRESEL. Select the preselected load point.
BASE LIMIT Limits preselected load to the nominal base load control curve.
(Optional with PEAK)
PEAK LIMIT (Optional) Limits preselected load to the peak control curve.
BASE Select base temperature control load point.

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Unit Operation - Turbine (Gas) GEK116689A

PEAK (Optional) Select peak temperature control load point.

Table 2. Mode Select & Master Control Options

2. Master Reset Target

Selecting the Master reset target resets the Master Reset Lockout function. This target must be
selected so that the unit can be restarted following a trip.

D. Definition of Terms
Spinning Reserve The minimum load control point based on generator output. The spinning reserve
magnitude in MWs can be found in the control specifications (5-10% of rating is a
typical value).
Preselected Load A load control point based on generator output. The preselected load point is
adjustable within a range designated in the Control Specification. The preselected
load point is normally set below the base load point. If the unit has peak load
capability (optional), the operator can select to limit preselected load control by
either the base limit or peak limit. If base limit is selected, the output will be limited
to the nominal base load control curve. If peak limit is selected, the output can be
controlled anywhere between nominal base load control curve and the peak limit.
Baseload This is the normal maximum loading for continuous turbine operation.
Peak Load (Optional) This is the maximum allowable output permitted for relatively long-duration,
emergency power requirement situations consistent with acceptable turbine parts
life. Peak Load operation will accrue factored fired hours at a rate greater than
nominal. Refer to GER 3620 for peak operation maintenance implications.

Table 3. Definitions & Terms

E. Supervisory Remote Equipment

Supervisory equipment is normally functionally the same as the equipment described in the cable
connected master panel. However, it may differ somewhat in metering and indications. Refer to the
supervisory manufacturer's instruction manual for details.

F. Annunciator System

Alarms are displayed on the HMI operator screens. Before clearing an alarm, action should be taken
to determine the cause and perform the necessary corrective action.

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GEK116689A Unit Operation - Turbine (Gas)

g GE Power & Water

General Electric Company
www.gepower.com

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GE Energy Learning Center Dec-2013

Start Check Database Frame 9FA GAS FUEL - TYPICAL

General Electric Company will not accept any liability whatsoever for the work undertaken on the
basis of this document.
This information has been released for training purposes only as a basic troubleshooting guide by GE
Power & Water, Energy Technical Training .

NOTE: This document is Proprietary & Confidential and should not be copied, or in any way transferred to other organizations without the written permission of GE. This
document is provided for training purposes only. Setpoint values, levels and control logic should all be verified at site by construction and commissioning before the unit is
released for commerical operation. This document can then be updated as needed to reflect an actual "as-built" status. Setpoint values, levels and control logic identified here
should not be considered accurate due to the flexible structure of the MKVI control system. General Electric Company will not accept any liability whatsoever for the work
undertaken on the basis of this text.

Start Check 0

Start Check permissive requires all three Compressor Inlet TC's to be healthy...
(1) within high and low limit constants
Comp Inlet AND
Thermocouples (2) have no more than a 10F ( 5.5C ) spread
Disagree L86TCI Compressor Inlet TC's CT-IF-1, 2, 3 are one input used to automatically compensate start-up fuel stroke
reference (FSR) as local ambient air temperature moves above or below the ISO benchmark of 59F ( 15C ).
Locate these TC's on MLI 0415.

StartCheck_9FA_DualFuel_12-2013_299104 1 of 5 Proprietary
GE Energy Learning Center Dec-2013

An IGV Health Check...

(1) IGV position must be correct ( closed )
(2) Servo 90TV-1 diagnostic OK
(3) LVDT feedback transducers 96TV-1 & 96TV-2 diagnostic OK
Any one of these in fault will cancel the start permissive. When shutdown the hydraulic loaded IGV's actuator
IGV Control Valve will hold the inlet guide vanes in the closed position. In operation the IGV's will open and close automatically as
Fault a function of MKVI output signal to the 90TV-1 servomotor. Given the size of the 9FA and the sensitivity to
L3IGVFLT compressor air flow we do not provide any operators manual override, nor do we provide any way for the
operator to manually command the IGV's.
When placed into IGV Temperature Control the MKVI will automatically generate an advanced IGV open
command signal to optimize Gas Turbine exhaust gas temperature for HRSG and Steam Turbine start up time
lags.
The I&C department can manually position the IGV's for calibration and or troubleshooting with the GT
Customer Permissive This is a hardwired switch provided for customer use from the DCS.
to Start Plant Operators will need to question their site controls Architectural Engineer and discover the full set of
l3cp circumstances which control this switch.
The GE MKVI control provides for hard-wired manual Emergency Trip pushbuttons.
Typically the only switch provided by GE is a single pushbutton located on the MKVI panel front. The site controls
Architectural Engineer can add additional pushbuttons in series with this panel mounted switch. For example it
has become customary for site AE's to place MKVI Emergency Trip pushbuttons in the control room at the
operators main control panel. Any one pushbutton "open" will produce a unit Emergency Trip. Emergency Trips
Emergency Stop PB should not to be confused with GT Normal Fired Shutdowns . While it is the operators responsibility to manually
L5ESTOP1 Emergency Trip the GT if needed, this is not the normal way to shutdown a loaded GT and should be used only if
the operator has good reason to believe the GT or Generator are in danger. The problem with using the
Emergency Trip unnecessarily is the large thermal shock which produces rapid and unneeded parts life
degradation. Use if the Emergency Trip function if needed, but have a good reason. The switch on the MKVI is a
push to open, retained open device. Before any restart the operator will need to manually attend the pushbutton
and physically reset, or "close" any open switch. Site AE's will also typically use pushbutton hardware of this type
The GT Fire Protection Panel is alerting the MKVI control that it has faults.
The problem can range from incorrect voltage supply to internal PLC faults to broken field devices. Can be
Fire Protection
caused by 1). low tank pressure; 2). closed isolation vavles at tank manifold and/or pilot supply line and/or at
System Problem
local zone isoltation
L30CC
Plant Operators will need to work with site I&C and remedy all faults.
Reference the site specific Fire Protection system documentation found within the site O&M manual
The MKVI control has internal communication faults between the individual processors.
Control System Fault - At the core of TMR technology is the ability for a control to compare logic processed by independent processors;
Start Inhibit "R" or redunancy. With communications is question, the ability to benefit from data supplied by independent
L3SFLTSC processors is also question. TMR benefits may be partially degraded or completely lost. MKVI internal
communication highways should be fully restored.

StartCheck_9FA_DualFuel_12-2013_299104 2 of 5 Proprietary
GE Energy Learning Center Dec-2013

When operating correctly the SSOV system issues a start permissive when...
(1) the MKVI internal logic is sending CLOSED signals to both the SSOV Vent VA13-18 and the Fuel Gas SSOV VS4-
SSOV Start-Up 4
Permissive AND
L3FGSSOV_SUP (2) the MKVI sees both the SSOV Vent VA13-18 and the Fuel Gas SSOV VS4-4 indicating CLOSED via the
hardwired valve position limit switches
Reference GEK-116384 for a description of the Leak Tests associated with the SSOV System
Isolation Valve
Closed Limit Switch Monitors Isolation valves at inlet bleed heat. Isolation valve must be open. Check limit switch.
Median
Start Check 1
The start permissive monitors health of the four flame detectors; 28FD-xx devices.
Flame Detector
Any flame detector which registers a flame intensity greater that 20%, with the Minimum Speed Relay "dropped-
Trouble
out" or L14HM = 0 will prevent a start.
L28FDSCK
L14HM Drops-Out at speeds < 13.5 % or = 0 and Picks-up > 14.0 % or = 1.
An HMI protective which prevents inadvertant starts by a mistaken keystroke.
Control = OFF
Operator can initiate a "Start" command via the HMI only after first selecting a Control "Mode" other than "OFF" -
L43O
Select CRANK, FIRE, or AUTO.
This permissive monitors health of Hydraulic Pressure header which services control valves and IGV.
Pressure devices placed on the hydraulic header must not be in alarm; switches 63HG-1, -2, -3, or 63HG-1, -2
Hydraulic Protective and PT-96HQ-1 must indicate minimum pressure. For liquid fuel units : 63HL-1, -2, -3 . 20TV-1 or 20 FG-1
Trouble solenoids stuck closed. Gas valve or IGV calibration being performed. LF Stop Valve Limit switch 33fl not closed.
L86HD
See devices on the "Hydraulic/Lift Oil Piping Schematic" ML-0434 with settings seen on site specific Device
Summary ML-0414
The Generator Breaker needs to be open else the GT will not start. 52GX-1 generator breaker status.
Generator Breaker
Generator breaker has been tripped by an automatic protective device or manually. Intentional breaker open
Close/Open Status
during normal shutdown or breaker was tripped by MK VI, GPP relay(s), DGP or customer device due to a fault
L52GX
requiring disconnect from the grid.
This permissive monitors Lube Oil Tank Temperature for a minimum value.
Lube Oil must be > 75 F ( 23.9 C ) by tank TC's ~ LT-OT-3 & LT-OT-4 to satisfy this minimum permissive.
Lube Oil Tank Temp Note:
Normal (1) Auto control of the Lube Oil Tank Heaters varys on a site specific basis. On sn 299104 the MKVI switches on
L26QN heaters at any temp < 84 F ( 28.9 C ).
(2) A lube pump should be in operation when the heaters switched "ON"
(3) for Operating Temperatures see the most recent revision of GEK-32568
Start Check 2

StartCheck_9FA_DualFuel_12-2013_299104 3 of 5 Proprietary
GE Energy Learning Center Dec-2013

This prevents a start if any MKVI Trip is active with L4T logical at "1".
Loss of Master
If use of the Master Reset pushbutton does not unlatch the "trip" then investigation is needed.
Protective
***NOTE*** In all cases, following any MKVI Trip, the plant should investigate, develop a root cause analysis and
L4Y
instigate corrective action before a GT re-start.
This prevents a start if any MKVI Trip is active with L4T logical at "1" AND any of the MKVI hardwired internal trip
Master Protective relays ETR's or PTR's are faulted OR if the unit fails a "Gas Fuel Leak Test".
Startup Trip/Lockout
L4Y ***NOTE*** In all cases, following any MKVI Trip, the plant should investigate, develop a root cause analysis and
Permissive monitors health ofinstigate corrective
Compressor Bleedaction
Valvesbefore a -2,
VA2-1, GT -3,
re-start.
-4 by monitoring open and closed
Comp Bleed Valve position switches located on each valve, 33CB1,2,3,4,5,6,7 & 8.
Fault Position A start permissive is given when all four valves correctly indicate "OPEN".
Lockout These valves are part of the compressor "stall" protection and need to stay open during start-up and during
L86CBI normal fired shutdowns once the generator breaker is opened.
Static Starter LCI
Ready to Start LCI must report "Ready-to-Start" - No faults within LCI or associated breakers
l3ss rs
Permissives looks at 4 situations and initiates a permissive IF…
Hydrogen Start (1) ESOP MCC start contacter 72ESX is not picked-up ( 88QE is not running )
Check (2) Generator Gas Pressure is OK (> 15 psig, 1 barg)
L3STCK_HGEN (3) H2 Analyzers #1 & #2 are not in Local Status
(4) Seal Oil Drain is not in Alarm
Comp Oper Limit BH Inlet Bleed Heat control valve VA20-1 is monitored for health.
Start Check While the valve is fail-safe "open" ( FO ) it needs to be closed for start-up.
L3BHSTCK Refer to the unit specific GEK the P&ID MLI-0432 and MLI-A010 unit specific Control Spec.

Start Check 3
This prevents a start if any MKVI Trip is active with L4T logical at "1".
Master Protective
If use of the Master Reset pushbutton does not unlatch the "trip" then investigation is needed.
Trip
***NOTE*** In all cases, following any MKVI Trip, the plant should investigate, develop a root cause analysis and
L4T
instigate corrective action before a GT re-start.
Minimum Speed
The permissive requires the Minimum Speed Relay be "dropped-out" or L14HM = 0.
Signal
L14HM Drops-Out to "0" at speeds < 13.5 % of rated and Picks-Up to a "1" with speeds > 14.0 %
L14HM
Permissive monitors health of GT & Generator Vibration Velocity seismic transducers.
Vibration Start
Each bearing cap will have 1 or 2 externally mounted Seismic Transducers.
Inhibit
ALL GT AND Generator bearing cap seismic transducers must be healthy (none in fault).
L39VD3
Reference GEK-111082 & ToolboxST Turbine Block Library ( GEI-100680 )

StartCheck_9FA_DualFuel_12-2013_299104 4 of 5 Proprietary
GE Energy Learning Center Dec-2013

EGD Link to the

The permissive monitors health of communications between the Generator Excitation and the MKVI.
Exciter is Bad
Communications must be in good health. Check cables and communication links.
L30COM EXFLT
EGD Link to LS2100
(L1 or L2) Fault The permissive monitors health of communications between the LCI's and the MKVI.
L30COM_L1FLT & At least one LCI must have communications with the MKVI. Check cables and communication links.
L30COM L2FLT
EX2100 Ready to The permissive monitors readiness of the Generator Excitation.
Start L3EX RS Excitation must broadcast an ability to start.

Start Check 4
This permissive monitors the health of Hazardous Gas Detection system.
Haz Gas System Start A start is denied IF ...
Check Any monitor indicates a fault OR any monitor indicates a high gas level in either the Turbine Compartment, GCV
L3HGSTCK Compartment or Generator Collector.
Refer to the Device Summary ML-0414 for HI & HI-HI device set points

Aux. Ready to Start

Auxiliary Check - Health check. Gas & LF servos must pass MKVI diagnostics. A fault in any single case will casue a Trip.
Servos L3ACS=1 for a premissive.
All IO Packs All MKVI input / output packs a healty and communicating. Control the I/O packs on the GTC panel (also check
Communicating logics & Diag Alarms) Check Ethernet Netwok connectors. Reboot the I/O pack, if established check in the logic.
Multiple Start Multiple Starts permissive must be "False" (L2FZ=0); no multiple starts in effect. Starts delay timer may be
Permissives activated, wait before the timer finish and restart.

Sensor Faults The GT Input Signal Processing protection module has detected failed devices ( sensors ).
Inhibit Start Plant Operators will need to work with site I&C and restore faulted devices to good health.
L3SENS_F Reference advice under GEH-6810 L3SENS_A.

StartCheck_9FA_DualFuel_12-2013_299104 5 of 5 Proprietary
 GEK 110608

GE Power Systems

Checklist, Prestart Mode Generator and Related Auxiliary

Equipment

These instructions do not purport to cover all details or variations in equipment nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance. Should
further information be desired or should particular problems arise which are not covered sufficiently for
the purchaser’s purposes the matter should be referred to the GE Company.[insert Disclaimer]
© 2002 GENERAL ELECTRIC COMPANY
 Checklist, Prestart Mode Generator and Related Auxiliary
GEK 110608 Equipment

I. GENERAL

Determine the mode of the equipment listed, then check the associated indication in the column provided.
Refer to the table of contents for data pertinent to the generator, hydrogen system, and exciter.

Equipment and Mode

1. Generator gas pressure between 0.5 and 30 psi

2. Hydrogen purity of scavenged gas ABOVE 85 per cent at each end of generator

3. Hydrogen in-use supply bottle FULL, or supply adequate for startup

4. Water supply to generator gas coolers ON

5. Armature circuit breaker OPEN

6. Excitor Datalink "OK" and Status = OFF

Determine the mode of the equipment listed, then check the associated indication in the column provided.
Refer to the table of contents for data pertinent to the generator, hydrogen system, and exciter.

Indication

1. Visual inspection of pressure gage on hydrogen control cabinet

2. Visual inspection of purity gage on hydrogen control cabinet

3. Visual inspection of pressure gage on hydrogen manifold

4. Visual inspection of shut-off valve, and hand test for OPEN position

5. Panel indicating light showing breaker OPEN

6. EX2100 Running status = STOPPED

GE Power Systems
General Electric Company
One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354

2
 g
GEK 111084c
Revised, October 2012
Grammatical Corrections Only

GE Energy

Startup/Shutdown Sequence and Control

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 111084c Startup/Shutdown Sequence and Control

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Startup/Shutdown Sequence and Control GEK 111084c

TABLE OF CONTENTS

I. GENERAL .................................................................................................................................................. 4
II. SPEED DETECTORS ............................................................................................................................... 4
III. STARTUP CONTROL .............................................................................................................................. 5
IV. CONTROL MODE DISPLAY AND OPERATING CONDITION....................................................... 7
V. FIRED SHUTDOWN................................................................................................................................. 7

LIST OF FIGURES

Figure 1. Startup Sequence Flow Diagram ............................................................................................................ 8

Figure 2. Startup Sequence..................................................................................................................................... 9

LIST OF TABLES

Table-1 Detector/Relay tags with Description and Speed Activation set point ..................................................... 4

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
without prior permission of the copyright owner.
GEK 111084c Startup/Shutdown Sequence and Control

I. GENERAL

Reliable starting, operating and safe shutdown of a Gas Turbine (GT) requires the application and
utilization of logic and permissives in combination with proper sequencing of command signals to the
critical safety systems and auxiliaries. Systems and auxiliaries that are critical for reliable starting and
safe shutdown include the GT Lube Oil System; Starting means – Load Commutating Inverter (LCI), Dry
Low Nox (DLN) and Fuel Gas system, Exciter/Generator combination, and the electrical system.

For a successful start-up, it is imperative that all GT related equipment is operating/ functioning
optimally, and accurate feedback signals indicative of the status/state of these devices are available for
utilization in the designed sequence.

During startup and shutdown sequence, these signals are critical because a large portion of the control
logic associated with actuating control devices is also enabling protective circuits. These circuits are also
utilizing device status and condition as permissive to proceed with the starting of shutdown sequence.

Startup and shutdown cycles have been optimized to reduce low cycle fatigue on hot gas path
components, and provide customers with the ability to obtain additional benefits like “purge credits.”

II. SPEED DETECTORS

An important part of the startup/shut-down sequence control of the turbine is proper speed sensing:
Table-1 below outlines the Detector/Relays along with description and speed activation set point.

Table-1 Detector/Relay tags with Description and Speed Activation set point
Detector/Relays Description Activation Percent
L14HR Zero Speed Detector Approximately 0% speed
L14HM Minimum Firing Speed Relay Approximately 14% speed
L14HA Accelerating Speed Detector Approximately 50% speed
L14HS High Speed Relay Approximately 95% speed
L14HT On Turning Gear Speed Relay Approximately 1.5% Speed

The zero-speed detector, L14HR, provides the signal to the Turbine control system when the shaft line is
at standstill and as soon as the shaft line starts rotating. This signal plus L14HT speed relay - indicating
that the turning gear is running – forms the permissive for the LCI/Static Starter engagement and
operation.

The minimum speed detector L14HM indicates that the turbine has reached the minimum firing speed
and also initiates the combustion system purge sequence prior to ignition. With these initiating signals
and permissives, the static starter is then given a command to go to purge speed. Once the purge sequence
is initiated, purge speed will be maintained until the purge timer has elapsed (times out). At this point in
the start sequence, the shaft–line will commence coasting down until the dropout of the L14HM
(minimum-speed relay).

NOTE

The dropout of 14HM provides several permissive functions in the startup of the
gas turbine after shutdown.

4 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Startup/Shutdown Sequence and Control GEK 111084c

The acceleration speed relay L14HA pickup indicates that the turbine has reached approximately 50% in
the acceleration cycle. The high-speed sensor L14HS pickup indicates that the turbine is at 95% operating
speed. After the pickup of L14HS, the inlet guide vanes will open and the accelerating sequence is
complete.

Should the gas turbine and generator bog down, after completing the start sequence and synchronization
with the Grid, the high speed relay L14HS will drop out at the under frequency speed setting.

At 95 % speed with the generator neutral in the correct verified position, the Exciter will “flash” the
generator field. The generator will start generating an output voltage which will rise to the nominal value
on the generator nameplate. The unit will now be at Full Speed No Load FSNL. At FSNL the digital set
point is 100.3% speed with the Generator Circuit Breaker (GCB) open. At this point the startup sequence
is virtually complete since the unit is operating and ready to be synchronized to the HV network.

Approximately 0.5 second after 14HS drops out, the generator breaker will trip open and the digital
setpoint will be reset to 100.3%. After the opening of the generator breaker, the compressor bleed valves
will open and inlet guide vanes will close as a function of corrected speed. The actual settings of the
speed relays are programmed in the controllers as constants and are listed in the Control Specifications
(MLI-A010).

III. STARTUP CONTROL

The startup control operates as an open loop control in with the use of preset levels of the fuel command
signal, Fuel Stroke Reference, FSR. The levels set are “FIRE”, “WARMUP, and “”ACCELERATING”.
The Control Specifications provide the correct/acceptable settings calculated for the fuel anticipated from
the fuel wobbe index. For reliable startup, the FSR levels must be set in the turbine control system.

Startup control FSR signals operate through the minimum value gate to insure that speed control and
temperature control can limit FSR if required. During the startup sequence, rates of increase in speed and
exhaust temperature are restricted to protect the turbine parts from excessive mechanical and thermal
stresses. The rates of acceleration and temperature rise are controlled independently by the closed loops
of the speed and temperature control systems.

The fuel command signals are generated by in the startup software. In addition to the three startup levels,
the software has the capability to set the maximum and minimum FSR with provisions for manual control
of FSR. The manual FSR control is accomplished via a FSR GAG pushbutton. When utilizing manual
FSR control, the operator can insert a value lower than the current FSR value to take control from the
current control command or a higher value to act as a not-to-exceed limit.

While the shaft line is at rest electronic system checks are performed on the stop/speed ratio valve, the
gas control valve, accessories, the voltage supplies, and Generator Protection Panel (GPP). If all systems
are “healthy” and functional without any system errors, trip latches or communicating errors at this time,
the operator display will be normal and the “SHUTDOWN STATUS” will be displayed on the Human
Machine Interface (HMI) screen.

Activating the Master Operation Switch from “OFF” to an operating mode will activate the ready circuit.
If all protective circuits and trip latches are cleared, the “STARTUP STATUS” and “READY TO
START” messages displayed to indicate the turbine will accept a start signal. Pressing the “START”
Master Control pushbutton will introduce the start signal to the panel.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
without prior permission of the copyright owner.
GEK 111084c Startup/Shutdown Sequence and Control

The start signal energizes the Master Control and Protection circuits (the L4 circuit), and starts the
necessary auxiliary equipment. If the shaft line is at standstill, the turning gear will start. With the unit on
turning gear the start-up status message “STARTING” is displayed on the HMI screen.

When the turbine rotational speed is above the turning gear speed > 6 RPM, the shaft line will
break-away the turning gear starting clutch from the rotor The Static Starting System will engage, then
continue accelerating the shaft line to purge speed. Once the static starter has accelerated the shaft line to
purge speed, the purge timer will start timing operation. During the purge cycle, air flow through the
turbine will purge the turbine and Heat Recovery Steam Generator (HRSG) in combined cycle
configuration of any residual combustible mixture by forcing approximately four volume changes of air
through the system, exhaust, out the stack. At the end of the purge cycle, the LCI de-engerizes the
generator and the turbine speed is allowed to decay below firing speed (14HM drop-out speed). At this
point the static starter maintains the turbine at the minimum firing speed.

When turbine speed reaches the firing level (14HM pickup), startup control FSR is set at the “FIRING”
Level. The firing timer, K2F, is started, and fuel flow is enabled. When flame detector output signals
indicate the establishment of flame – successful ignition and cross firing - in the combustion chambers,
the warm-up timer, K2W, starts and the startup fuel command FSR is set to the “WARM UP” FSR level.
If ignition and cross firing is not achieved, before the 60 second cross firing timer times out, the control
system will automatically revert to the purge sequence and will attempt a second firing sequence. The
warm-up time is provided to minimize thermal stresses during the initial part of the startup.

At the end of the warm-up period, the startup control FSR command is ramped to the maximum
allowable startup value. That is defined as FSR acceleration control. At this point, the starting device is
set at the position to provide maximum acceleration torque. At about 80% speed, the turbine efficiency
has increased sufficiently to the point that the gas turbine is now self-sustaining and the static starter is no
longer required. The static starter begins to roll off to its reset sequence upon reaching 90% speed. At this
point the IGV’s that were closed during the startup to prevent compressor surge will be opened to the
FSNL position.

It is important to mention that although startup control establishes the maximum FSR fuel command,
other controls may reduce FSR to perform their critical control functions that may cause the turbine to
reach the temperature control, speed control, or acceleration limit. However, the lowest FSR command is
always selected to control fuel. The limiting control parameter will always be displayed on the control
panel.

NOTE

Time to FSNL and loading rates will depend on the system configuration
(Simple or Combined) in conjunction with the type/vintage of Dry Low NOx
(DLN) system and the type of fuel being used (cold or heated).
For these limitations, please refer to the Combustion System documentation for
your particular Gas Turbine.

6 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Startup/Shutdown Sequence and Control GEK 111084c

IV. CONTROL MODE DISPLAY AND OPERATING CONDITION

Display Condition
STARTUP Startup Program
ACCEL Acceleration
Control DROOP SPEED Speed Control
TEMP Temperature control

The startup cycle has been designed to moderate the highest combustion reference during acceleration.
By programming a low acceleration rate control setting during startup. It also aids smooth transition to
speed control at the end of the startup sequence. The startup sequence time is extended to an optimum
time to minimize strains produced on hot gas path parts in mid-acceleration cycle.

The minimum FSR limit is incorporated into temperature, acceleration and speed control circuits. This
prevents these controllers from driving FSR below the value that would cause flameout during a transient
condition.

When the generator breaker closes, the startup control FSR command is quickly ramped to “MAX” FSR.
Refer to Figures 1 and 2 for startup sequence and control descriptions.

V. FIRED SHUTDOWN

A normal shutdown is initiated by selecting STOP from the HMI startup screen. This process is reversible
until the generator breaker is opened and the turbine speed falls below 95% at about 5% negative power.
This activates the L94X signal. If the generator breaker is closed when the stop signal is initiated, FSR
and load are reduced at the standard unloading rate until the reverse power relay opens the generator
breaker. When this occurs, FSR is ramped down as a function of corrected speed until the turbine reaches
L14HM. Fuel to the turbine is shut off by clamping FSR to zero and tripping the stop valve closed when
the flame detectors indicate a loss of flame. Fuel is shut off 60 seconds after turbine speed falls below the
run-back speed setpoint (K60RB approximately 20% Actual Turbine –Generator Speed (TNH) in the
event that flame detection is maintained.

After fuel is shut off, cooldown sequence logic ensures slow roll on turning gear until the cooldown time
expires.

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 7
without prior permission of the copyright owner.
GEK 111084c Startup/Shutdown Sequence and Control

Figure 1. Startup Sequence Flow Diagram

8 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Startup/Shutdown Sequence and Control GEK 111084c

Figure 2. Startup Sequence

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 9
without prior permission of the copyright owner.
GEK 111084c Startup/Shutdown Sequence and Control

g GE Energy
General Electric Company
www.ge-energy.com

10 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
 Stator

Turbine Compressor Field

100% Stator

EX2000
Isolation
Xfrmr LCI 89SS-1 90% Speed
89ND -1

52G

GT Self Sustaining (60% Speed))

50%
LCI “RUN/TORQUE”
Fire/Warm Up Acceleration Begins
% of Synchronous Speed

Coast Down
708 RPM Purge Speed (23.6%) LCI, EX2100 Secured
95% Speed
Purge Timer Starts EX2100 to “Auto”
89SS-1 “Open”
15% Speed
89ND-1 “Close”
TG
14% Speed LCI “STOP”
6-8 RPM
0 1 Min 5-15 Min (Simple Cycle) 2 Min 1 Min 3-5 Minutes Time (minutes)
LCI-06
 ! " # $ %
')& ')&&
8 : 8
'(& '(&&

''& ''&&
! 0 1 2!3
'&& 1 2!3 4 2 '&&1 4 )&&& '&&&
15 6 4 6 " 7 '&&1 4 8 " 7%
!' ( ) *

/& 26 4 6 2 /&&

.& .&&
!% &

-& -&&
26 "%

&
,& 1 56 ,&&
!"# $

+& +&&

*& 9 8% *&&
1 : IBH Valve-% flow
9 8%
)& )&&

(& 1 56 (&&
;;" <

'& '&&

& &
& ( * , . '& '( '* ', '. (& (( (* (, (. )&
;'% 8 7 = 6
;(% :!
 # $ $#+
! " # $ %
')& ')&&
$: 8 7
'(& '(&&
26 "%
''& ''&&
1 2!3
'&& '&&&
!' ( ) *

/& ! 0 /&&
1 2!3 4 2 '&&1 4 )&&&
15 6 4 6 " 7 '&&1 4 8 " 7%
.& .&&
26 4 6 2
!% &

-& -&&

&
,& 1 56 ,&&
!"# $

+& +&&

*& 9 8% *&&
9 8%
)& )&&
1 :
(& (&&
;;" <

'& '&&
1 56
& &
& ( * , . '& '( '* ', '. (& (( (* (, (.
;'% 8 7 = 6
;(% :!
 # $ $#+
! " # $ %
')& ')&&
$: 8 7
'(& '(&&
26 "%
''& ''&&

'&& '&&&
1 2!3
!' ( ) *

/& ! 0 /&&
1 2!3 4 2 '&&1 4 )&&&
15 6 4 6 " 7 '&&1 4 8 " 7%
.& 26 4 6 2 .&&
!% &

-& -&&

&
,& 1 56 ,&&
!"# $

+& +&&

*& 9 *&&
8%
)& )&&
1 : 9 8%
(& ;;" < (&&

'& '&&
1 56
& &
& + '& '+ (& (+ )& )+ *& *+ +& ++ ,&
;'% 8 7 = 6
;(% :!
 GEK 116369
March 2009

GE Energy

Synchronization

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 116369 Synchronization

I. GENERAL

In order to synchronize the Generator to the Grid four conditions must be satisfied: phase sequence match-
ing, phase angle matching, frequency matching, and voltage magnitude matching.

The phase sequence of the three phases of the generator must be the same as that of the grid. This might be
deviate only at initial stages of operation or during maintenance the reminder of the time it is in synchronous
with the grid.

The phase angle between the voltage produced by the generator and the voltage of the grid must be zero.
This can be observed readily by observing the simultaneous occurrences of peaks or zero crossing of the
sinusoidal waveform.

Frequency of the voltage produced by the generator and the voltage on the grid must be same.

Magnitude of the voltage produced by the generator must be same as that of the grid voltage.

If phase angle is not matched and the generator breaker is closed, the generator will experience high inrush
current, which may damage the stator. If the breaker is closed while the generator frequency is below the
grid, the generator will act as a motor, with the pattern of grid and generator frequency similar to Figure 1.

Figure 1.

If generator frequency does not match the grid and the breaker is closed then there is possibility of damaging
the poles of the generator. The difference in voltage may result in high MVAR flow.

All of the above-mentioned four criteria can be achieved either manually or automatically. When the turbine
- generator satisfies all of the above criteria automatically through the control system and synchronizes with
the grid it is called as auto-synchronization. Auto-synchronization covers four functions: automatic speed
matching, automatic voltage matching, generator breaker closing command, and synchronizing check pro-
tection. The operator can manually match the speed and voltage by raising/lowering the speed and voltage
from the operator interface. Thus the operator can manually satisfy the criteria for synchronization and
close the generator breaker referred to as Manual Synchronization.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Synchronization GEK 116369

The speed and voltage matching code control the speed governor and the exciter, as required, to attain synch
condition. Once the synch condition is achieved the breaker selected for synchronization is automatically
closed. The breaker is closed when the synchroscope is at the 12 o’clock position.

A synchronization monitor mode is provided which permits completion of the first two functions but in-
hibits the breaker close command to facilitate operator inspection and testing. Manual synchronizing also
utilizes the same synchronizing check protection as applied for auto-synchronization.

II. HARDWARE DESCRIPTION

The synchronizing system interfaces to the breaker close coil through the terminal board. Three contacts
in series are used to create the generator breaker close command subject to the condition that all external
contacts must be true. The three relay contacts are as follows:

1. 25P is a permissive relay, indicating that the turbine-generator is prepared for synchronization, at full
speed with generator breaker open. It is driven from three redundant controllers (<R>,<S>, and <T>)
with the result being voted in a two out of three fashion. This is driven by controller application code.

2. 25A is the sync-check relay, indicating that generator/line phase difference and other parameters are
within allowable limits and synchronization is permissible. This relay is driven from the three redun-
dant protection boards (<X>,<Y>, and <Z>) to be independent from the controllers. Refer to item III.4
for additional details.

3. 25 is the precision auto-sync relay. It is the last relay to close when performing an auto- synchronization
operation and includes the breaker time anticipation function discussed below. This relay is also driven
from the three redundant controllers.

Each of the three controllers and three protection boards has its own power supply. The final output relays
are powered from the diode high select of the three power supplies for the three controllers.

III. SEQUENCE DESCRIPTION

1. Operator selects AUTO SYNC at the operator interface or from the DCS. Note that the operator can
select SYNC OFF to abort the auto–synchronization process at any time.

2. Auto-synchronizer adjusts Load Set-point up/down as required until turbine-generator frequency

matches line frequency. When a large deviation exists, the adjustment rate is fast. As the deviation is
reduced, the adjustment rate switches to the slow rate. For some applications, only one adjustment
rate is used for speed matching.

3. Auto-synchronizer adjusts AC Regulator reference by pulsing contact outputs (if this feature is pro-
vided) to match generator terminal volts with line volts.

4. Auto-synchronizer enables the sync-check relay 25A and energizes it whenever the following permis-
sive are satisfied:

• generator voltage within high/low limits

• line voltage within high/low limits

• generator frequency within high/low limits

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEK 116369 Synchronization

• line frequency within high/low limits

• generator/line voltage difference within limits

• generator/line frequency difference below maximum value

• generator/line phase difference below maximum value

5. Auto-synchronizer begins to perform breaker close calculations based on phase, slip, acceleration, and
anticipated time lead to compensate for breaker delay.

When a solution is calculated such that generator voltage and line voltage will be in phase at the time
of breaker closure, a breaker close command is issued. Once the generator breaker is closed, the auto-
synchronizer is inhibited from further use.

The auto-synchronizer will not allow the breaker to close with negative slip. Slip is the difference in fre-
quency of the generator with respect to that of the grid. Positive slip means that the generator is faster than
the grid. Positive phase means the generator is leading the grid; the generator is ahead in time, or the right
hand side on the synchroscope.

IV. INDICATIONS AND DISPLAYS

Parameters for display include generator voltage and frequency, line voltage and frequency, generator/line
voltage difference, generator/line voltage frequency difference (slip), generator/line phase difference (in-
cluding generator leading/lagging indications).

The auto-synchronizer provides self-adaptive correction to the breaker closure time up to certain limits.
Once a limit is reached, an alarm is provided.

Status indications include auto-sync selected/deselected, monitor mode selected, generator breaker open/
closed, voltage ok/not ok, AC Regulator raise/lower selected, frequency ok/not ok, Load Set-point
raise/lower selected, phase ok/not ok.

After synchronization if we observe the waveform pattern of the generator and the grid it should be as
shown below in Figure 2.

Figure 2.

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Synchronization GEK 116369

PAGE LEFT INTENTIONALLY BLANK

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 116369 Synchronization

GE Energy
General Electric Company
www.gepower.com

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 GEK 106866A
Revised, August 1999
Replaces LCGD03

GE Power Systems
Gas Turbine

Loading Characteristics – General

I. GENERAL

Once the unit has been synchronized either manually or automatically it can be loaded by several loading
sequences. For instance, a unit can be loaded manually or automatically up to a temperature control limit,
or a (KW) output load limit. More details on the actual control panel features are described in the Operation
section of this manual.

II. SYNCHRONIZING

Automatic synchronizing is accomplished using a microprocessor synchronizing circuit. The circuit inputs
are transmitted through an interface module. The interface module contains an isolation transformer for the
generator and line input signals and the breaker closing relay. The synchronizing software is part of the
SPEEDTRONIC computer.

For synchronizing, the unit is brought to 100.3% of rated speed. If the system frequency has varied enough
to cause an unacceptably high slip frequency a speed matching circuit in the synchronizer will adjust the tur-
bine governor to reduce the slip frequency and permit synchronizing.

For added protection a synchronism check relay is provided. It is used in series with both the auto synchroniz-
ing relay and the manual breaker close switch to prevent large out-of-phase breaker closures.

III. FULL-SPEED, NO-LOAD

The reason that the “Full-Speed, No-Load” adjustment is important is that it actually calibrates speed with
the called-for speed using the digital setpoint. The 100.3% setpoint will cause an increase in fuel command
necessary to raise the speed 0.3% above synchronous grid frequency. It is essential that the generator and
system frequency be matched within 0.33 Hz to synchronize quickly with the synchronizing relay. “Full-
Speed-No-Load” therefore is an important setting to assure proper speed for synchronizing.

IV. LOAD CONTROL

Speed load control increases fuel through the digital setpoint to maintain output value. Most units have three
values of output control; reference to the Control Specifications for settings is required.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 1999 GENERAL ELECTRIC COMPANY
GEK 106866A Loading Characteristics – General

1. Spinning Reserve — Once the generator breaker is closed, the turbine will load to this setting.

2. Preselected Load — This load is selected by giving the unit a second start signal after it is at spinning
reserve.

3. Load Limit — The load is not selectable but is an output protection beyond which the unit is not
permitted to operate. It is normally the material limit for the generator.

V. MANUAL LOAD

The operator may increase or decrease load between no-load and base temperature control line. The loading
is accomplished by raising or lowering the digital setpoint.

VI. TEMPERATURE CONTROL

Temperature control is initiated by the switch 43BP. In this mode of control load is increased automatically until
a temperature control limit is reached. Load is then held at a constant firing temperature as more fully described
in the Temperature Control text. Turbine output in this mode of control is a function of ambient temperature.

VII. LOAD RATE

Load may be increased from FSNL to base load according to the following table for 4% droop:

Non-DLN DLN
Model Series Manual Normal Fast Load Manual Normal Fast Load
MS5001P 30 sec 4 min 30 sec 30 sec 4 min 2 min
MS6001B 30 sec 4 min 30 sec 30 sec 4 min 2 min
MS7001EA 6 min 12 min 90 sec 6 min 12 min 3 min
MS7001FA 6 min 12 min 90 sec 6 min 12 min 4 min
MS9001E 6 min 12 min 90 sec 6 min 12 min 3 min
MS9001EC 6 min 12 min 90 sec 6 min 12 min 3 min
MS9001FA 6 min 12 min 90 sec 6 min 12 min 4 min
MS6001FA 6 min 12 min N/A 6 min 12 min N/A

NOTE
Manual load control is provided for full convenient rapid adjustment of load. It is not
intended to be used to raise load to rated output without interruption. Frequent use of
manual setpoint control to reach rated load rapidly can reduce hot gas path parts life.
Similarly excessive use of “Fast Start” can also reduce hot gas path parts life.

GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354
 g
GEK 116772
December 2010

GE Energy

Operation of Hydrogen-Cooled Turbine-Generator

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.
GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

The below will be found throughout this publication. It is important that the significance of
each is thoroughly understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.

2 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

TABLE OF CONTENTS

I. INTRODUCTION ................................................................................................................................... 4
II. FINAL INSPECTION BEFORE STARTING THE GENERATOR FOR THE FIRST TIME ...... 4
A. Connection ......................................................................................................................................... 4
B. Generator Voltage.............................................................................................................................. 4
C. Resistance Temperature Detectors .................................................................................................... 4
D. Casing Tightness................................................................................................................................ 4
E. Collector Rings and Brush Rigging ................................................................................................... 5
F. Insulation Resistance ......................................................................................................................... 5
G. Shaft Sealing System ......................................................................................................................... 5
H. Clearances .......................................................................................................................................... 5
I. Rubbing and Vibration ...................................................................................................................... 5
J. Bearing and Seal Housing Insulation ................................................................................................ 5
K. Exciter ................................................................................................................................................ 5
L. Hydrogen System .............................................................................................................................. 5
M. Gas Coolers........................................................................................................................................ 5
III. STARTING THE UNIT AND SYNCHRONIZING............................................................................. 6
IV. SYNCHRONIZING THE GENERATOR: STARTING THE UNIT & GOING ONLINE ............. 6
A. Steam Turbine-Generator Configuration ........................................................................................... 6
B. Gas Turbine-Generator Configuration ............................................................................................... 7
V. NORMAL ONLINE OPERATION ..................................................................................................... 10
A. Steam Turbine-Generator Configurations ....................................................................................... 10
B. Gas Turbine-Generator Configurations ........................................................................................... 10
VI. NORMAL EXCITATION SYSTEM SHUTDOWN .......................................................................... 11
A. Steam Turbine –Generator Configurations ...................................................................................... 11
B. Gas Turbine-Generator Configurations ........................................................................................... 11
VII. EXCITER TRIP DURING GENERATOR-CRITICAL EVENTS .................................................. 11
A. Steam Turbine-Generator Configurations ....................................................................................... 11
B. Gas Turbine-Generator Configurations ........................................................................................... 11
VIII. OPERATION OF THE GAS COOLERS ........................................................................................... 12
IX. OPERATION WITH UNBALANCED ARMATURE CURRENT .................................................. 12
A. Terminal voltage is from 100 to 105% of rated ............................................................................... 12
B. Terminal voltage is from 95 to 100% of rated ................................................................................. 12
X. POWER FACTOR ADJUSTMENT.................................................................................................... 14
XI. EFFECT OF LEADING AND LAGGING POWER FACTOR ....................................................... 14
XII. RECTIFIER LOAD .............................................................................................................................. 15
XIII. LOSS OF FIELD ................................................................................................................................... 16
A. General............................................................................................................................................. 16
B. Inspection Following Trip-Out ........................................................................................................ 16
XIV. GROUNDED FIELD WINDING......................................................................................................... 16
XV. GENERATOR LOAD CAPABILITY ................................................................................................. 17

LIST OF FIGURES

Figure 1. Negative Phase Sequence Current from the Magnitudes of the Three Phase Currents
(For Case of No Zero Phase Current).................................................................................................... 13
Figure 2. A Typical Reactive Capability Curve ................................................................................................... 15

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 3

GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

I. INTRODUCTION

A large high-speed turbine–generator is a precision built piece of equipment of great complexity designed
to operate in conjunction with a turbine in a modern power plant with a minimum of manual control.
These machines are constructed to operate continuously for long periods of time without shutdown. To
properly operate one of these large generators requires close following of operating guides and
procedures for the particular unit. Although operating practices differ to some extent between various
operators, there are many general operating rules, which can be applied universally. This instruction is
included as a guide for operating a turbine-generator and does not purport to cover all details or variations
in operating procedures.

II. FINAL INSPECTION BEFORE STARTING THE GENERATOR FOR THE FIRST TIME

One of the most important periods in the life cycle of a turbine-generator is during the initial startup.
During this period each component part of the unit is checked and tested for proper installation and
operation. Before shipment, the generator is given standard factory tests, which include the following:

ƒ Mechanical inspection
ƒ Mechanical balance
ƒ Overspeed run
ƒ Measurement of cold resistance of armature and field windings
ƒ Insulation resistance measurements
ƒ Dielectric tests
ƒ Leakage tests
ƒ Resistance temperature detector tests

Even though all these tests are made in the factory, it is considered essential to repeat many checks just
prior to operating the unit in the power plant.

The following inspections and preliminary checks should be made just before the generator is started for
the first time.

A. Connection
Check the armature connections with the Connection Outline.

B. Generator Voltage
See that the voltage on the generator nameplate corresponds with the line voltage.

C. Resistance Temperature Detectors

The resistance temperature detectors should be checked to determine that they are indicating
properly.

D. Casing Tightness
The generator should be checked for gas leaks. After the generator has been completely assembled,
air pressure should be introduced to the generator frame and the frame and piping carefully checked
for leaks in accordance with the instructions for Gas Leakage Tests given in the instructions on
Hydrogen Cooling.

4 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

E. Collector Rings and Brush Rigging

The collector rings should be carefully inspected for any scratches or rough spots. The brushes should
be fitted to the curvature of the collector rings. The position of the brushes and rigging should be set
in accordance with Brush Rigging and Collector Rings instructions.

F. Insulation Resistance
The insulation resistance should be taken in accordance with instructions on Insulation Testing.

G. Shaft Sealing System

The shaft sealing system must be in operation (refer to instructions on Hydrogen Cooling).

H. Clearances
The fan and other rotor clearances should have been checked during erection. Records should be
reviewed to ascertain that this has been done.

I. Rubbing and Vibration

As specified in the instructions for bringing the turbine up to speed, checks should be made to insure
that there is no rubbing between the rotating and stationary parts of the generator, and that operation
of the combined turbine and generator rotors is free from excessive vibration.

J. Bearing and Seal Housing Insulation

The bearing and seal housing insulation should be checked with an insulation resistance meter in
accordance with instructions on Insulation of Bearing and Seal Housing.

K. Exciter
The exciter should be checked thoroughly in accordance with the Excitation Equipment section.

L. Hydrogen System
The hydrogen system should be checked in accordance with the instructions on Hydrogen Cooling.

M. Gas Coolers
The gas coolers should be checked as follows. Water supply to all cooler sections should be turned on
full. The cooler vents should be open to bleed out all entrapped air. The cooler discharge lines should
be checked to ascertain that nearly an equal flow of water is discharging from each cooler section.
With the vents “cracked open” to provide for continuous venting, the water discharge may be
throttled to obtain the desired rate of flow.

Cooler water should be throttled on the discharge side of the coolers to avoid air pockets and unstable
operation with low flows. Where valves are located both before and after the coolers, care should be
taken to maintain a positive pressure on the coolers.

If condensate is used for cooling it may be necessary to connect the discharge from the vent lines to
the condenser in order to maintain an effective pressure for venting. The cooling water supply
pressure should be checked to determine that this pressure is within the designed operating pressure
for the coolers.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 5

 GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

III. STARTING THE UNIT AND SYNCHRONIZING

When starting the turbine-generator, it is recommended that a startup checklist be used to ascertain that
no items have been overlooked. The following items should be included on a checklist. These lists are
recommended and do not purport to cover all items to be checked on a specific installation.

This section describes the excitation system control overview. The document will provide an explanation
of any minimum required operator actions. This description applies to Operation of Generator Terminal
Fed Static Excitation Systems on Steam Turbine or Gas Turbine prime mover Applications. It applies to
control systems utilizing an EX2000 exciter and Mark* V turbine control, communicating via status <S>
arcnet data link. And, control systems utilizing an EX2100 or EX2100e exciter and Mark* VI or Mark*
VIe turbine control, communicating via Unit Data Highway (UDH) ethernet data link.

Two major configurations will be described. The first (section A) is for steam turbine–generators and the
second (section B) is for gas turbine-generator applications.

ƒ As the generator is brought up to speed, check the mechanical balance by taking shaft vibration
readings.
ƒ The resistance temperature detectors and field temperature should be checked frequently during
startup to ascertain that the winding temperatures are not excessive.
ƒ At 90% speed verify that the LCI is de-energized and that the circuit breaker between it and the
generator has opened.
ƒ Verify that the LCI exciter circuit breaker has been opened.
ƒ Verify that the breaker between the generator neutral and the grounding transformer is closed.

IV. SYNCHRONIZING THE GENERATOR: STARTING THE UNIT & GOING ONLINE
A. Steam Turbine-Generator Configuration

1. The following initial checks to be made:

a. Armature circuit breaker open

b. Main and spare field circuit breaker open

2. When the unit is turning slowly check for rubbing.

3. As the generator is brought up to speed, check the mechanical balance by taking shaft vibration
readings.

4. Check position of collector ring brushes on collector rings to see that they ride properly on the
rings.

5. Regulate the cold liquid flow valves to obtain the rated flow condition. The cold gas temperature
inside the generator will then be a function of cold liquid temperature and the losses during the
start sequence.

6. As the generator is brought up to speed, check the mechanical balance by taking shaft vibration
readings.

*
Trademark of the General Electric Company.

6 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

1. Before starting the Steam Turbine

The operator needs to verify all alarms in the exciter are cleared and the exciter is in Auto
Regulator Mode. All normal operator interaction with the excitation system can be via the
Turbine Control Panels’ primary operator interface (<I>, <HMI>, or DCS screen).

From the Turbine Control Panel primary operator interface, the operator reviews the
Generator/Excitation Control Display and should ensure the excitation system is clear of all
faults and is in Auto Regulator Mode. After this point, the operator does not need to initiate any
exciter control commands until auto synchronization is complete.

2. After starting the Steam Turbine

The Turbine Control Panel automatically initiates the exciter start command at 95% speed. The
start command is sent to the exciter automatically via the TCP. The exciter receives the start
command from the TCP over the control system data link. Upon receiving the start command,
the exciter automatically does a pre-start and turns on the excitation. After the excitation is
turned on, the exciter flashes the field for approximately 5-20 seconds. This will cause the
generator terminal voltage to build up to a level where the PPT can provide sufficient AC
voltage to allow the SCRs in the exciter rectifier bridge to fire. As soon as the bridge SCRs can
fire, the Auto regulator takes the Generator to 95% terminal voltage in 1-2 seconds.

After this point, the TCP continues with synchronizing sequence. The TCP controls voltage and
speed matching. The TCP synchronizer raises the Auto Voltage Regulator set point via the data link
until the voltage is within the dead band. After voltage matching and speed matching, TCP
synchronizes and closes the Generator or Line breaker. At this point the generator goes on-line. For
details of generator synchronization please refer to GEK 116369.

B. Gas Turbine-Generator Configuration

*
ƒ Before attempting a start, every effort should be made to complete the checkout of the Mark VI,
LS2100 and EX2100. All systems should be operating normally with no faults or alarms present
and all temporary jumpers should be eliminated.
ƒ The generator coolers should be operating normally with proper water flow.
ƒ The unit must be on turning gear with the motor controller selected for Auto.
ƒ Cooling water must be flowing through the “external” side of the LS2100 water-to-water heat
exchanger or overheating may occur in the LS2100 during the start sequence.
ƒ If the EX2100 source breaker (52ET or 41AC as applicable) is manually operated, it must be
closed prior to giving start command to unit to apply AC voltage to the EX2100 bridges.

1. The following additional checks to be made:

a. LCI controls are properly set per Turbine Operating Procedures

b. Generator grounding transformer breaker open

c. LCI safeties are reset and operational

d. Generator safeties are reset and operational.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

2. When the unit is turning slowly by means of the pony motor check for rubbing.

3. Check position of collector ring brushes on collector rings to see that they ride properly on the
rings.

4. Verify that hydrogen pressure and purity are at rated conditions.

5. Regulate the cold liquid flow valves to obtain the rated flow condition. The cold gas temperature
inside the generator will then be a function of cold liquid temperature and the losses during the
start sequence.

6. As the generator is brought up to speed, check the mechanical balance by taking shaft vibration
readings.

7. The resistance temperature detectors and field temperature should be checked frequently during
startup to ascertain that the winding temperatures are not excessive

WARNING

STARTUP OF A HYDROGEN COOLED GENERATOR IN AIR IS

SIGNIFICANTLY HARDER ON THE GENERATOR DUE TO THE
REDUCED HEAT TRANSFER PROPERTIES OF AIR. FOR THIS
REASON ANY LOW SPEED HOLD POINTS TYPICAL OF THOSE
ASSOCIATED WITH WATER WASH, PURGE AND HRSG WARMUP
MUST BE ELIMINATED. THE TRANSITION FROM TURNING
GEAR SPEED TO RATED SPEED MUST BE AS QUICK AS POSSIBLE.

Before starting the gas turbine, the operator needs to verify all alarms in the exciter are cleared and
the exciter is in Auto Regulator Mode. All normal operator interaction with the excitation system can
be via the Turbine Control Panels’ primary operator interface (<I>, <HMI>, or DCS screen). From
the Turbine Control Panel’s primary operator interface, the operator reviews the Generator/Excitation
Control Display and should ensure the excitation system is clear of all faults and is in Auto Regulator
Mode. After this point, the operator does not need to initiate any exciter control commands until auto
synchronization is complete.

The operator will verify all Static Starter faults are clear and then select the static starting
configuration on multiple gas turbine applications. See Operation of Static Starting System for Gas
Turbine Applications. The TCP puts the Exciter in LCI mode (manual). The LCI receives speed set
point commands from the LCI with associated current limits controls the rate of change. The higher
the current limit, the faster the LCI gets to the speed set point. The exciter follows 0-10V reference
from LCI via hardwire, or reference over data link. At low speed the LCI is self/force commutated…
as voltage on the stator builds it becomes load commutated. The LCI regulates field voltage to a
constant V/Hz limit at speeds below approx 30%. After approx 30% speed the V/Hz limit drops off
exp with speed.

All gas turbine static starting systems follow the same 5 phases of operation. Each phase of operation
is described below:

8 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

3. Acceleration to Purge Phase

After all starting permissives are satisfied; the unit begins the Acceleration to Purge Phase. The
static starter accelerates the train from turning gear (3-6 rpm) to 30% speed in about 2 minutes.

NOTE

Shaft train acceleration is achieved by applying variable frequency voltage and

current to the generator stator winding which produces generator rotor torque. In
general, the higher the current and voltage in the generator stator winding the
higher the torque on the generator rotor. While applying the stator current, the Load
Commutated Inverter (LCI, LS2100) provides the proper stator voltage levels based
on output frequency to ensure the proper V/HZ limits for the generator are
maintained.
4. Purge Phase

After Acceleration to purge phase, the static starting system begins the purge phase. This phase
varies from unit to unit, depending on the Gas Turbine exhaust plenum size. Units with an
HRSG require longer purge times. Turbine Controls Constant K2TV found in the Control
Constants Document (MLI:A010) specifies the exact purge time for the job specific unit. During
the purge phase the unit wobbulates to avoid amplification of any train critical speed.

5. Coast Down Phase

After the purge phase times out, the unit is allowed to coast down from 30% to 14% speed. This
takes approximately 2 minutes and no power is applied by the static starter at this time

6. Firing Phase

When the turbine train speed reaches 14% as it decelerates during the Coast Down phase, the
static starting system switches to the Firing phase. The static starter holds the unit at 14% speed
for approximately 1 minute and ignites the combustors.

7. Acceleration to Full Speed Phase

After the Firing phase, the static starting system switches to the Acceleration to Full Speed
phase. The Static Starting system accelerates the train from 14% speed to 90% speed in
approximately 5 to 6 minutes. During this phase, the gas turbine also contributes torque to the
acceleration of the train. However, the static starter stays on until the speed reaches 90% speed
where the Gas Turbine is self-sustaining. At this point the static starter is disconnected and the
GT takes the unit to 100% speed.

After the static starter shuts off at 90% speed

a) Verify that the LCI is de-energized and that the circuit breaker between it and the generator has
opened.

b) Verify that the LCI Transformer circuit breaker has been opened.

c) Verify that the breaker between the generator neutral and the grounding transformer is closed.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 9

GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

After verifying the conditions above, the exciter is automatically put back in to Auto Regulator
mode via the TCP. The Turbine Control Panel automatically initiates the exciter start command
at 95% speed. The start command is sent to the exciter automatically via the TCP over the data
link. The exciter receives the start command from the TCP over the control system data link.
Upon receiving the start command, the exciter automatically does a pre-start and turns on the
excitation. After the excitation is turned on, the exciter flashes the field for approximately 5-20
seconds. This will cause the generator terminal voltage to build up to a level where the PPT can
provide sufficient AC voltage to allow the SCRs in the exciter rectifier bridge to fire. As soon as
the bridge SCRs can fire, the Auto regulator takes the Generator to 95% terminal voltage in 1-2
seconds.

After this point, the TCP continues with synchronizing sequence. For details associated with
synchronizing the generator please review GEK 116369 (Synchronization). The TCP controls
voltage and speed matching. The TCP synchronizer raises the Auto Voltage Regulator set point
via the data link until the voltage is within the dead band. After voltage matching and speed
matching, TCP synchronizes and closes the Generator or Line breaker. At this point the
generator goes on-line.

Before any attempt is made to close the generator synchronizing breaker, the phase sequence of
the generator and the system should be checked to make absolutely certain that the phase rotation
of the generator and the line are the same. At this time a check of the synchronizing connections
should be made. As the damage resulting from improper synchronizing can be extremely great,
the above checks are essential.

After the above checks have been made, the generator should be synchronized.

V. NORMAL ONLINE OPERATION

A. Steam Turbine-Generator Configurations
After the unit is on-line, the exciter will regulate to the Auto Voltage Regulator set point last used to
synchronize. As the turbine is manually or automatically loaded with MW, the exciter will not
deviate from the synchronizing AVR set point, until the operator raises or lowers the exciter via using
the TCP exciter raise and lower push buttons on the TCP operator interface or selects TCP VAR or
PF control. Either one of these actions will re-establish a new Auto Voltage Regulator set point.

When the operator puts the TCP in VAR or Power Factor control, the exciter stays in Auto Voltage
Regulator and the TCP VAR/PF outer control loop raises or lowers the exciter AVR set point as the
power system dynamics change.

B. Gas Turbine-Generator Configurations

After the unit is on-line, the exciter will regulate to the Auto Voltage Regulator set point last used to
synchronize. As the turbine is manually or automatically loaded with MW, the exciter will not
deviate from the synchronizing AVR set point, until the operator raises or lowers the excitation using
the TCP exciter raise and lower push buttons on the TCP operator interface or selects TCP VAR or
PF control. Either one of these actions will re-establish a new Auto Voltage Regulator set point.

When the operator puts the TCP in VAR or Power Factor control, the exciter stays in Auto Voltage
Regulator mode and the TCP VAR/PF outer control loop raises or lowers the exciter AVR set point
as the power system dynamics change.

10 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

VI. NORMAL EXCITATION SYSTEM SHUTDOWN

A. Steam Turbine –Generator Configurations
During normal steam turbine shutdown, the turbine load is runback to zero and the turbine is tripped.
When the generator begins to motor, the Generator Protection Panel initiates a breaker open
command via reverse power function. This reverse power function utilizes a steam turbine valves
closed permissive to prevent a turbine over speed event.

After the breaker is opened and the unit is off-line, the steam turbine begins to coast down to cool
down speed. As the turbine coasts down, and drops below 90% speed, the TCP issues a normal
offline stop command to the exciter over the control system data link.

Upon receiving this normal offline stop command, the exciter does a full field voltage inversion for 5
seconds, removing energy from the field and allowing the generator terminal voltage to collapse
quickly. After this 5 second inversion the exciter stops firing the bridge, trips the AC breaker, and
fires the De-excitation module. The de-excitation module will short the field via SCR with a
discharge inductor or resistor. This will removed the remaining energy from the field winding and
further accelerate the generator terminal voltage decay.

B. Gas Turbine-Generator Configurations

During normal steam turbine shutdown, the turbine load is runback to zero and the turbine is tripped.
When the generator begins to motor, the Generator Protection Panel initiates a breaker open
command via reverse power function. This reverse power function utilizes a steam turbine valves
closed permissive to prevent a turbine over speed event.

After the breaker is opened and the unit is off-line, the turbine begins to coast down to cool down
speed. As the turbine coasts down, and drops below 90% speed, the TCP issues a normal offline stop
command to the exciter over the control system data link. Upon receiving this normal offline stop
command, the exciter does a full field voltage inversion for 5 seconds, removing energy from the
field and allowing the generator terminal voltage to collapse quickly. After this 5 second inversion
the exciter stops firing the bridge, trips the AC breaker, and fires the De-excitation module. The de-
excitation module will short the field via SCR with a discharge inductor or resistor. This will remove
the remaining energy from the field winding and further accelerate the generator terminal voltage
decay.

VII. EXCITER TRIP DURING GENERATOR-CRITICAL EVENTS

A. Steam Turbine-Generator Configurations
Any generator critical faults when on-line or offline will imitate an excitation system trip. Generally,
these are electrical faults that cause protective’s to energize the 86G lockout relay in the generator
protection panel. The excitation system will only receive a trip command via contact input (e.g., 86G
lockout relay contact) or via internally driven exciter trip fault. It is important to note, no exciter trip
commands are receive from the TCP via the data link. Only an emergency trip push button on the
86G lockout relay will produce a generator critical trip via operator intervention

B. Gas Turbine-Generator Configurations

Any generator critical faults when on-line or offline will imitate an excitation system trip. Generally,
these are electrical faults that cause protective’s to energize the 86G lockout relay in the generator
protection panel. The excitation system will only receive a trip command via contact input (e.g., 86G
lockout relay contact) or via internally driven exciter trip fault.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 11

 GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

It is important to note, no exciter trip commands are receive from the TCP via the data link. Only an
emergency trip push button on the 86G lockout relay will produce a generator critical trip via
operator intervention

VIII. OPERATION OF THE GAS COOLERS

The ventilating gas is circulated by the rotor fans through the generator in a closed system, the heat
absorbed by the gas being removed in the cooler sections by the cooling water. The generator data sheet
indicates the maximum amounts of water and the water temperature required for satisfactory operation.

If it should become necessary to clean the cooler sections while operating, the sections may be taken out
of service one at a time for cleaning without completely shutting down the unit. The maximum load
which may be carried with one cooler section out of service must be limited to the values given on the
data sheet. It is not necessary to remove hydrogen from the machine to clean the cooler sections if the
hydrogen seals around the tube sheets are not broken.

IX. OPERATION WITH UNBALANCED ARMATURE CURRENT

Large turbine-generators are rated on the basis of balanced load conditions. With balanced three-phase
load, the generator phase currents are equal in magnitude and are in symmetrical phase sequence. With
unbalanced load conditions, the phase currents and terminal voltages deviate from the ideal relationship
of balanced load, and a negative phase sequence armature current is imposed on the generator. Excessive
unbalanced loading results in extra losses and temperature rise which are generally not provided for in the
generator design. The extra losses appear primarily at the surface of the rotor, and generator capability
decreases with increase in the amount of unbalance.

Permissible balanced-load operation is defined by the generator reactive capability curves in terms of
generator kw and kvar. The generator is designed to operate at the kva capability in the range 95 to 105%
of rated terminal voltage under balanced conditions.

Permissible unbalanced load operation is defined by the generator reactive capability curves, the
maximum phase current capability, and the permissible negative sequence current. Under unbalanced
conditions, the generator may also be operated at the kva capability, calculated using the average of the
line-to-line voltages and the average of the phase currents, providing the maximum phase current does
not exceed the following values:

A. Terminal voltage is from 100 to 105% of rated

Maximum phase current = rated armature current for the operating hydrogen pressure

B. Terminal voltage is from 95 to 100% of rated

Maximum phase current =

rated armature current for the operating hydrogen pressure X rated line-to-line voltage
average of line-line voltages

12 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

An evaluation of a given unbalanced load condition can be made by comparing the actual negative
sequence armature current with the maximum permissible negative sequence armature current and by
comparing the maximum phase current with the capability listed above. If the maximum phase current
exceeds the limiting values listed above, or if the actual negative sequence current is in excess of the
maximum permissible, one of the following corrective measures should be taken:
ƒ Reduce the unbalanced load.
ƒ Increase the generator power factor.
ƒ Reduce the generator kva load.
ƒ Reduce the terminal voltage (down to a minimum of 95% of rated voltage).
The maximum permissible negative phase sequence current is 0.08 per unit, where base armature current
corresponds to the generator capability at the particular operating conditions (hydrogen pressure, cold gas
temperature, power factor, etc.).

The actual negative sequence armature current may be calculated by use of Figure 1, provided there are
no zero phase sequence currents. For example,

Let Ia = 0.880, Ib = 0.704, and Ic = 0.757, in per unit of base armature current.
Then Ib/Ia is 0.8 and Ic/Ia is 0.86.
From Figure 1, I2/Ia is 0.125 and I2 = 0.125 x 0.880 = 0.11, in per unit of base armature current.

A helpful rule, applying with less than 0.05 per unit negative phase sequence current, is that the positive
phase sequence component is approximately the average of the three phase currents, and the negative
phase sequence component is approximately the maximum deviation of any of the phase currents from
the average.

0.20
0.70

0.75
0.15

0.80
I I
2 b
Ia 0.10 0.85 Ia
Ib
Ia
0.90
0.05
0.95

1.0
0 0.8 0.9 1.0
Ic I a = largest of three phase currents
Ia I b = smallest of three phase currents
I c = third phase current of intermediate value

Figure 1. Negative Phase Sequence Current from the Magnitudes of the Three Phase Currents
(For Case of No Zero Phase Current)

Operation according to these unbalanced load recommendations is not intended to be within limits of
guaranteed temperatures or limits of temperatures established by standards for operation at the machine
rating. The departures from temperature limits established by standards will be small, however, and the
temperatures generally will be within the safe temperature range that would be expected if the machine
was operated over the range 95 to 105% terminal voltage at rated balanced kva.
© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 13
GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

Generator unbalanced armature currents produce shaft torque pulsating at twice the line frequency with
magnitudes in per unit approximately equal to the per unit negative phase sequence armature current. The
pulsating torques also appear on the generator stator core. Spring-mounted stator cores in most of the
modern 3600 rpm generators (hydrogen-cooled and large air-cooled) will effectively isolate this pulsating
torque from the stator frame and foundation.

The magnitude of the extra losses and heating resulting from zero phase sequence armature current will
depend on the individual generator design (in particular the armature winding pattern) as well as the value
of the zero phase sequence armature current. Zero phase sequence loading of a particular generator
should be referred to the manufacturer for recommendation.

In the absence of data from the manufacturer, a conservative basis for zero phase sequence loading, or
combined negative phase sequence and zero phase sequence loading is the following. Combine the per
unit zero phase sequence, I0, and negative phase sequence, I2, current components according to equation
(1), and observe the same limitations for the resulting equivalent current, I1, as given for I2. This rule is
conservative, but generally should be adequate for the rather rare situations where it is necessary to
impose zero phase sequence loads on turbine-generators.

I′= ( I 2 )2 + (I O ) 2 (1)
Equation 1

X. POWER FACTOR ADJUSTMENT

When operating the generator singly, the power factor of the generator is determined by the power factor
which the load demands. However, when the generator is operating on a system or in parallel with other
machines, its power factor is determined by the generator field current. The power factor for the generator
may be adjusted by adjusting the field current; for overexcited (or lagging power factor) operation,
increasing the field current will lower the power factor, and decreasing the field current will raise the
power factor.

XI. EFFECT OF LEADING AND LAGGING POWER FACTOR

All turbine-generator units are designed to meet a particular rating. This rating includes the power factor,
in addition to kva, voltage, and speed. However, turbine–generator units, because of system conditions,
are usually operated at other than rated power factor, and it is important for the operators to know the
capabilities and limitations pertaining to this type of operation. These are shown by a reactive capability
curve which is included in the generator section of the operator’s manual. A typical curve is shown in
Figure 2. This curve is plotted in per unit values for illustrative reasons.

To illustrate the relationship of kw, kvar, and kva, a vector diagram has been added to the lower left-hand
corner of the curve. This shows that at any operating point on the reactive capability curve, the values of
kw and kvar may be vectorially added to give the resultant kva.

In addition, a small Vee curve has been included on this reactive capability curve to illustrate the portions
of the V-curve capability limits on the reactive capability curve.

It is significant that the majority of switchboards in power stations are provided with kw and kvar meters,
so that the reactive capability curves may be used directly. Therefore, it is not usually necessary when
operating a generator to know the kva.

14 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

An inspection of Figure 2 shows that the portion of the curves extending between the rated power-factor
lagging line and the 0.95 power-factor leading line is an arc of a circle whose radius of 1.0 per unit kva
corresponding to the rating at various hydrogen pressures. In this region the kva is limited by armature
winding temperature limitations.

In the region of operation between the rated power-factor line and zero power-factor lagging
(overexcited) the kva is limited by the temperature rise of the field winding. In the region of leading
power factor or in the under-excited range, rated kva can usually be carried to 0.95 power-factor leading.
From this point the kva must be reduced to maintain safe end-iron temperatures on the armature core.

Another consideration for low leading power-factor operation is steady-state stability. It has been found
by tests that a typical turbine-generator unit using static type voltage regulator will have a steady-state
pullout considerably below the operating range permitted by the heating limitations shown on the curve.

XII. RECTIFIER LOAD

Large turbine-generators are rated on the basis of armature current with negligible deviation from a pure
sine wave. If part of the generator AC output is converted to DC, harmonic currents generated by the
rectifying process will flow in the generator armature windings. These harmonic currents result in extra
losses, primarily at the surface of the rotor, which are not normally provided for in the generator design.

Field Winding
Heating Limitations
+1.0
Rated P.F. Lagging

+0.8

+0.6 Armature Winding Heating Limitations

1 .0
0 .8 0.5 PSIG [3.4 kPa (Gauge)][0.035kg/cm2 (Gauge)] Hydrogen Pressure
+0.4 0 .6
0 .4 15 PSIG [103.4 kPa (Gauge)] [1.0 kg/cm2 (Gauge)]Hydrogen Pressure
O.P.F. Lag
0 .2 O.P .F.
“Vee Curves”
+0.2 Lead
Field Amps
30PSIG[206.8 kPa (Gauge)] [2.10 kg/cm2 (Gauge)]Hydrogen Pressure
0 Per Unit
0 0 .2 0 .4 0. 6 0.8 1 .0
0
0 .2 0.4 0 .6 0 .8 1.0 1.2 1.4 90°F (32.2°) H2O
Kilowatts- per- Unit
-0.2
0.95 P.F. Lagging
-0.4

-0.6 Armature Core

End Iron Heating
Limitation
-0.8 A
KV
KVAR
-1.0 Ѳ
KW
Cos Ѳ = Power Factor

Figure 2. A Typical Reactive Capability Curve

The decrease in generator capability is a function of the magnitude of each of the harmonic currents and
of the electrical design of the specific generator in question. Before any rectifier load is connected to the
generator, it is recommended that the schedule of harmonic currents be submitted to the General
Electrical Company for use in determining the corresponding reduction in generator capability.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 15

 GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

XIII. LOSS OF FIELD

A. General
Operation of a turbine-generator connected to a system without field current will cause excessive
field heating. The degree to which this heating will occur depends on several conditions including the
initial load on the machine, the manner in which field current is lost, and the manner in which the
generator is connected to the system. When excitation is lost, the generator tends to overspeed and
operates as an induction generator. This overspeed normally results in a reduction in load due to the
characteristics of the turbine governor, an increase in armature current, and possible low voltage at
the generator terminals, and is accompanied by high rotor currents.

These rotor currents will flow both through the field winding (providing the field winding has been
short-circuited or is connected through the field discharge resistor) and through the rotor body,
completing the circuit through the rotor coil wedges. The rotor body currents will cause extremely
high and possibly dangerous temperatures in a very short time, particularly where the currents flow
across the wedges at the ends of the rotor body. The time required for the heating to become
dangerous depends on the conditions of loss of excitation. But in general, this time is short, being
only a matter of seconds rather than minutes for a machine with a completely open field winding.

In addition, opening of the field circuit with the machine carrying a load (the field not short-circuited
through the field discharge resistor), may subject the winding to high and possibly dangerous
voltages from the inductive effects of the winding.

If excitation is lost by accidental tripping of field breaker, the breaker should be immediately reclosed
without shutting down the machine.

If the machine is discovered to be operating without field for an unknown interval of time, it should
be immediately tripped off the line and shut down for an inspection to determine the degree of rotor
damage from heating.

Relays are now available which determine when a machine has started slipping due to loss of
excitation. Since this effect occurs in a relatively few seconds after the loss of field, and if such relays
are employed to trip the machine from the line, damage from overheating will be prevented and the
machine may be put back in service as soon as the defect in the excitation system has been remedied.

B. Inspection Following Trip-Out

If the machine is tripped off the line due to any of its protective devices, no attempt should be made
to resynchronize the machine before the cause of the trip-out is determined.

Following a trip-out due to the differential phase relays, both the armature and field windings should
be tested and otherwise inspected before attempting to resynchronize.

XIV. GROUNDED FIELD WINDING

It is general practice to operate a turbine–generator with the excitation system ungrounded. If an

accidental single ground occurs on the generator field operating on an ungrounded system, no change in
the excitation system occurs at the time of the ground, and the machine may be removed from the system
without the risk of system interruption or costly damage to the generator field. As soon as possible after a
ground is indicated, the generator should be removed from the line and the difficulty repaired. In no case
should a generator be allowed to remain on the system for any appreciable time after a ground occurs.

16 © General Electric Company, 2010. GE Proprietary Information. All Rights Reserved.

 Operation of Hydrogen-Cooled Turbine-Generator GEK 116772

XV. GENERATOR LOAD CAPABILITY

The generator should not be operated at any loads above the nameplate rating even though its operating
temperature rise may be well below the guaranteed temperature rises and the cooling water temperature
may be lower than that specified on the data sheet. The generator is designed to give long, trouble-free
life for continuous and intermittent operation at rated output, and loading beyond the nameplate rating
encroaches on the design margins built into the machine.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 17

GEK 116772 Operation of Hydrogen-Cooled Turbine-Generator

g GE EnergyGeneral Electric Company

www.gepower.com

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SIZE DWG NO SH REV

A 106T0341 1 -
DATE
REV ZONE DESCRIPTION APPROVED
(YYYY-MM-DD)
- Initial release per ECO0079166 2012-10-30 SEE PLM

THIS DOCUMENT SHALL BE REVISED THIS DRAWING TO BE REVISED IN MICROSOFT

IN ITS ENTIRETY. ALL SHEETS OF THIS WORD ONLY. THE SOURCE FILE IS STORED IN
DOCUMENT ARE THE SAME REVISION A SECURE DATABASE
LEVEL AS INDICATED.

REVISION DESCRIPTION IS FULLY

STATED ON FIRST SHEET OF
DOCUMENT

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIGNATURES & DATES
GENERAL ELECTRIC COMPANY
DRAWN - Flute Yan GE ENERGY GENERATOR
Schenectady, NY, USA
DRAWN DATE (YYYY-MM-DD) – 2012-10-30

CHECKED - SEE PLM

CHECKED DATE (YYYY-MM-DD) – SEE PLM GENERATOR ELECTRICAL DATA

Siddhirganj 335 MW Combined Cycle Power
ENGR - SEE PLM

ENGRG DATE (YYYY-MM-DD) – SEE PLM

FIRST MADE FOR: 324X039 MLI/COST CODE: C902
ADDITIONAL APPROVALS SIZE CAGE CODE DWG NO
SEE PLM SYSTEM FOR REGISTERED
APPLIED PRACTICES INFORMATION A 106T0341
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ESTIMATED GENERATOR DATA

Customer: Isolux Ingenieria S.A

Station/Project: Siddhirganj 335 MW Combined Cycle Power
Generator Number: 324X039
Generator Type: 324-U5XG

GENERATOR RATING
Data for Proposal No/Electrical Design: 720103G2 Sep 8 2011
ATB 2 332000 kVA 3000 RPM 15000 Volts 0.8 PF 60 psig (414 kPa) 40 °C Gas 265600 kW 12779 Amps
625 Field Volts 26 Ft (7.9 m) Alt 0.45 SCR 50 Hz 3 Phase WYE Connection

Exciter Rating
Type Static
1245 kW 625 Volts 1992 D.C.Amps Field Amps @ Generator rated Load 1830

Total temperatures are guaranteed not to exceed: Insulation Class Temperature Rise
Stator coils: 106 °C by embedded detector Armature F B
Field coils 120 °C by Resistance Field F B
Collector Gas Rise 20 °C by RTD

COOLING WATER REQUIREMENTS @ GENERATOR RATING (C901 - Data)

Generator Output: 332000 kVA
Loss to Coolers: 2450 kW
Inlet Water Temperature: 30 °C
Outlet Cold Gas Temperature 40 °C
Coolant 100% Water
Maximum Fouling Factor: 0.001 ft2 hr °F/ Btu (0.1761 m2 °K/ kW)
Total Water Flow Required: 2700 GPM (612.9 m3/hr) (total for all coolers)
Coolant temperature Max 46 °C
Head Loss Per Cooler: 17.29 Feet of Water (51.6 kPa)
Maximum Operating Pressure: 125 psig (862 kPa)

DIELECTRIC TESTS (Between coils and ground, 50/60 hertz AC for 1 min)
Stator 31000V
Rotor 5300V

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

GE ENERGY GENERATOR
Schenectady, NY, USA
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REACTANCES (Per Unit): Direct Axis Quadrature Axis

Saturated Synchronous Xdv 2.23 Xqv 2.13
Unsaturated Synchronous Xdi 2.23 Xqi 2.13
Saturated Transient X'dv 0.300
Unsaturated Transient X'di 0.335 X'q 0.550
Saturated Sub transient X"dv 0.205 X"qv 0.205
Unsaturated Sub transient X"di 0.255 X"qi 0.255
Saturated Negative Sequence X2v 0.205
Unsaturated Negative Sequence X2i 0.255
Saturated Zero Sequence X0v 0.145
Unsaturated Zero Sequence X0i 0.145
Saturated Leakage Reactance Xlv 0.175
Unsaturated Leakage Reactance Xli 0.190

FIELD TIME CONSTANTS (Seconds @ 125 °C)

Open Circuit T'd0 6.4 T'q0 0.55
Three Phase Short Circuit Transient T'd3 0.77 T'q 0.14
Line To Line Short Circuit Transient T'd2 1.31
Line To Neutral Short Circuit Transient T'd1 1.6
Short Circuit Sub transient T"d 0.031 T"q 0.031
Open Circuit Sub transient T"d0 0.045 T"q0 0.083

ARMATURE DC COMPONENT TIME CONSTANTS (Seconds@ 100 °C)

Three Phase Short Circuit Ta3 0.45
Line To Line Short Circuit Ta2 0.45
Line To Neutral Short Circuit Ta1 0.34

ARMATURE WINDING SEQUENCE RESISTANCES (Per Unit)

Positive R1 0.0035
Negative R2 0.0176
Zero R0 0.0082

Reactance, Resistance and Time Constant data may be interpreted per IEEE 115, Part II.
The base reactance (“UNIT”) is calculated by the armature kV squared / MVA.
Base reactance = 0.6777 Ohms
Rotor Short-Time Thermal Capacity, (I2)2t 8s
Turbine-Generator Combined Train Inertia, WR2 853540 lb-ft2 (35968 kg-m2)
Turbine-Generator Combined Inertia Constant, H 5.345 kW-s/kVA
Three Phase Armature Winding Capacitance 1.3828 PF
Armature Winding DC Resistance (Per Phase) 0.001158 Ÿ (100 °C)
Field Winding DC Resistance 0.3366 Ÿ (125 °C)
Field Current At Rated Kva, Armature Voltage, & PF 1830 A
Field Current At Rated Kva, Armature Voltage, 0 PF Lagging* 2121 A
( *For Systems Study Only - Not Allowable Operating Point )
©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

GENERAL ELECTRIC COMPANY

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Schenectady, NY, USA
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MACHINE SATURATION DATA

S/1.0 = 0.0341 Machine saturation may be calculated from the data of curves A and B of
S/1.2 = 0.1998 “ESTIMATED SATURATION AND SYNCHRONOUS IMPEDANCE CURVES”.
“S/1.0” is the field amp difference from B to A divided by the field amp of A at 1.0 pu voltage.
X/R RATIO
X/R = 120 X/R ratio equals “XPP/DV” * base reactance / armature DC resistance at 100 C

©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
GE CLASS II (INTERNAL NON-CRITICAL)
SIZE CAGE CODE DWG NO

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GE ENERGY GENERATOR
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©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy Generator Proprietary Technical Information that
belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of restricted private use. All persons, firms, or
corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any, or all such
information except as expressly authorized in writing by the General Electric Company, GE Energy (USA), LLC and/or its affiliates.
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 GEI 74478d
Revised April 2009

GE Energy

Periodic Operational Inspection, Lubrication and Tests

Hydrogen-Cooled Generators

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEI 74478d Periodic Operational Inspection, Lubrication and Tests

The expected normal operating conditions and parameters are prescribed in the various sections of the
Instruction Book. The required parameters, which vary with specific operating conditions, may be best
maintained by periodic inspection and tests. Inspection and test should be scheduled at regular intervals
consistent with the instructions and good operating practice. The following is a typical schedule which
should be amended as required by specific operating instructions.

I. EACH SHIFT

1. Check the water flow, termperature and vent to heach hydrogen cooler.

2. Check the generator collector rings and brushes, exciter commutator and brushes.

II. DAILY

1. Rotate the handle on the seal oil strainer.

2. Check the differential pressure between the machine gas and the seal oil.

3. Check the oil level in the tanks.

4. Check the liquid detector sight glasses.

5. Check the hydrogen purity and flowmeter indication.

6. Check the operation of the seal oil vacuum pump and the possible excessive accumulation of moisture.

7. Check all the indicating instruments.

III. WEEKLY

1. Start and run the emergency seal oil pump.

2. Test the visual and/or audible alarm system.

3. Determine the effectiveness of exciter ventilation and air filters

IV. 3-6 MONTHS

1. Isolate the liquid detectors and fill the float chamber to test the alarms

2. Check the calibration and operation of all the alarm devices and/or contacts.

3. Lubricate the three-way valves in the hydrogen piping.

4. Calibrate the gas analyzer

5. Test the bearing insulation

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Periodic Operational Inspection, Lubrication and Tests GEI 74478d

V. 6-12 MONTHS

1. Check the calibration and operation of all the alarm devices and/or contacts.

2. Test the hydrogen relief valve for a possible leakage into vent line.

3. Check the pressure setting of the relief valve at hydrogen manifold.

4. Check the calibration of all the indicating instruments.

5. Test the hydrogen valves and the packing for leakage.

VI. GENERATOR MAINTENANCE OUTAGE

1. Drain and clean the seal oil strainer.

2. Clean the flowmeter tubes.

3. Inspect motors.

4. Inspect gear and vacuum pump.

Table 1. Manual Lubrication Chart

Lubricate
Mechanism / Device Every 3–6 Special Instructions
Other
Months
Seal Oil Unit Vacuum Pump X Refer to Turbine Generator Instruction Book
AC Pump Motor GP Refer to Turbine Generator Instruction Book
DC Pump Motor GP Refer to Turbine Generator Instruction Book
Gear Motor GP X Refer to Turbine Generator Instruction Book
H2 System Plug Valve X Flowserve – Nordstrom 421Lubricant/Sealant

GP= General purpose grease GE Specification D6A2C5

Shell Alvania No. 2
Atlantic No. 54
Esso-Andock No. 260

For reference:

GEK103566, Creating an Effective Maintenance Program

GEK103616, Protection of Unassembled Generator Components during Shipment and prior to Startup

GEK110146, Protection of Assembled Generators, during Shipment, Storage and prior to Startup

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEI 74478d Periodic Operational Inspection, Lubrication and Tests

GE Energy
General Electric Company
www.gepower.com

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

 g
GEK 75512m
Revised, January 2012

GE Energy

Generator Protection

SECTIONS OF THE ORIGINAL DOCUMENT

WERE REMOVED FOR TRAINING PURPOSES.

THIS COPY ONLY CONTAINS TABLES 1

(ALARMS) AND 2 (PROTECTION
RECOMMENDATIONS).

02/2014 PW - GE ELC

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
GEK 75512m Generator Protection

Table 1. Alarms
SIGNAL DEVICE RANGE SETTING NOTES
MACHINE TEMPERATURES

GENERATOR WITH
BRUSHLESS EXCITER
BRUSHLESS EXCITER RTD -20° to 80°C Generator Cold Check Ventilation
OUTLET AIR Gas +40°C

GENERATOR WITH STATIC

EXCITATION
COLLECTOR AIR IN RTD or TC -30° to 70°C 65°C In: Check Ventilation
COLLECTOR AIR OUT RTD or TC -20° to 90°C AIR IN + Out: Check Filters
20°C
GENERATOR FIELD TRANSDUCER 0° to 150°C Reduce field current by adj.
MVAR load.
STATOR COIL (SLOT) RTD 0 to 100°C for H2O See Ref. 2
0 to 150°C for H2O
and Air
OTHER ALARMS
BEARING VIBRATION VIBRATION --- --- See Recommendation in this
DETECTOR publication.
BEARING OIL TEMP HIGH - --- --- See Turbine Section of
Instruction Book
NEGATIVE SEQUENCE RELAY Balance or reduce load.
CURRENT See Recommendation for
"Unbalanced Armature
Currents."

GENERATOR OVERVOLTAGE RELAY --- Over 1.05 pu Reduce machine voltage.

voltage

Collector / Cab Fire Detection Heat Detector 325°F (Not

System - High Temperature Adjustable - Set
By Device)

Collector / Cab H2 Detection H2 Detector 0% to 100% LEL 10% LEL High

System - Presence of Hydrogen Alarm & 25% LEL
High-High Alarm

AIR COOLING (if applicable)

COLD AIR RTD -30 to 70°C

HOT AIR RTD -10 to 90°C
LOCAL OVERHEATING (if
applicable)
— —
CORE MONITOR LEVEL (if CORE MONITOR See Recommend. for "Local
applicable) Overheating."
MACHINE HEATING (if SIGNAL See Recommend. for "Local
applicable) VALIDATION Overheating."
DEVICE

@From operating pressure

†Two switches

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without prior permission of the copyright owner.
Generator Protection GEK 75512m

Table 1. Alarms (Cont'd)

SIGNAL DEVICE RANGE SETTING NOTES

SEAL OIL SYSTEM (if applic.)

DIFF SEAL OIL PRESSURE LOW DIFF. PRESSURE 3 psid [20.7 kPa] See Ref. 3
2
SWITCH [211 g/cm ]

DRAIN ENLARGEMENT LIQUID LEVEL --- See Ref. 3

LIQUID DETECTOR FULL DETECTOR

EMERGENCY PUMP RUNNING RELAY --- See Ref. 3

FILTER DIFF. PRESSURE HIGH DIFF. PRESSURE 10 psid [69 kPa See Ref. 3

(if applicable) SWITCH (differential)]

[703 g/cm2 (diff.)]

—
VACUUM TANK OIL LEVEL FLOAT SWITCH +4/-6 in See Ref. 3

HIGH/LOW (if applicable) [+102/-152 mm]

—
MAIN PUMP MOTOR THERMOSTAT See Ref. 2

OVERLOAD (if applicable)

EMERGENCY PUMP MOTOR THERMOSTAT --- See Ref 2

OVERLOAD (if applicable)

HYDROGEN GAS SYSTEM

COOLER HOT GAS TEMP HIGH RTD or TC 0-100°C

COOLER COLD GAS TEMP RTD or TC 0-70°C

HIGH/LOW

COMMON COLD GAS TEMP RTD 0-70°C

HIGH (if applicable)

MACHINE GAS TEMP HIGH METER RELAY 0-100°C See Ref. 4

MACHINE GAS PRESSURE PRESSURE SWITCH +4/-2 psi @ See Ref. 4

HIGH/LOW [+27.6/-13.8 kPa]

[+281/-14.1
g/cm2]

MACHINE GAS PURITY LOW METER RELAY or 50-100°C 0-100°C 90% See Ref. 4

TRANSMITTER

GENERATOR CASING LIQUID LIQUID DETECTOR --- See Ref. 4

DETECTOR FULL

†Two switches @From operating pressure

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 33
without prior permission of the copyright owner.
GEK 75512m Generator Protection

Table 1. Alarms (Cont'd)

SIGNAL DEVICE RANGE SETTING NOTES

STATOR COOLING WATER

SYSTEM (if applicable)

INLET TEMP HIGH RTD or TC 0-70°C 2°C OVER See Ref. 2

MAX.
INLET FLOW LOW FLOW SWITCH See Ref. 3

INLET PRESSURE LOW PRESSURE SWITCH See Ref. 3

LIQUID HEADER OUTLET TC 0-100°C See Ref. 3

TEMP HIGH

BULK WATER OUTLET TEMP RTD 0-100°C See Ref. 2

HIGH

CONN RING TEMP HIGH (if TC 0-100°C See Ref. 2

separately cooled)

CONN RING FLOW LOW (if FLOWMETER See Ref. 3

separately cooled)

HV BUSHING OUTLET TEMP TC 0-100°C See Ref. 2

HIGH
HV BUSHING FLOW LOW FLOWMETER 3 gpm LOW [189 See Ref. 3
ml/s]

MAIN FILTER DIFF PRESSURE DIFF PRESSURE 0-15 psid [0-103 kPa 8 psid [55 kPa Change filter before 7 psid
HIGH SWITCH (differential)] [0-1.05 (differential)] [48 kPa (diff.)] [492 g/cm2
2
kg/cm (diff.)] [562 (diff.)]
g/cm2(diff.)]

CONDUCTIVITY HIGH TRANSDUCER 0-10 mho/cm [0-10 0.5 & 9.9 Change resin on first alarm.
μS/cm] μmho/cm [0.5 & Trip manually on second alarm
9.9
mS/cm]
—
TANK LEVEL HIGH/LOW FLOAT SWITCH +4/-4 inches Check main pump

[+102/-102 mm]
RESERVE PUMP RUNNING PRESSURE SWITCH 0-150 psi [0-1.03 MPa] 10 & 20† psi Check cause and correct
2
[0-10.5 kg/cm ] below normal [69
& 138 kPa][0.7
& 1.41
kg/cm2]
RUNBACK INITIATED RELAY NONE PRESET

†Two switches
@From operating pressure

34 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
Generator Protection GEK 75512m

Table 2. Summary of Protection Recommendations

Fault Type Recommendation

Electrical Faults
Stator Overcurrent Runback 8 or 7
Stator Ground Fault Trip Type 1
Stator Phase-to-Phase Fault Trip Type 1
Over-voltage Alarm (Restore normal voltage)
Over-volts/Hertz Trip Type 2 (or 1)
Field Overexcitation Trip Type 2 (or 1)
Field Ground Trip Type 2 (or 1)
Loss Of Excitation Trip Type 2 (or 1)

System Faults
Unbalanced Armature Currents Trip Type 2 (or 1)
Loss of Synchronism Trip Type 3
Abnormal Frequency Operation See Turbine Instructions
Breaker Failure Use Breaker Failure Protection
System Back-up Trip Type 3
Voltage Surges Use surge arrestors

System Operations
Transmission Line Switching Limit magnitude of power step
High Speed Reclosing See detailed recommendations
Subsynchronous Resonance See detailed recommendations
Inadvertent Energization See detailed recommendations

Mechanical or Thermal Faults

Bearing Vibration Trip Type 6 (or 1)
Synchronizing Errors Use check relays
Motoring Trip Type 3 (or 2 )
Stator Overtemperature Alarm (Trip Type 6)
Loss of Coolant to Gas Coolers Trip Type 6 (or 1)
Reduced Seal Oil Pressure Reduce H2 pressure & load
Local Overheating Runback 8 (or 7) or Trip Type 5
Loss of Stator Coolant Runback 7 or Trip Type 1
High Water Conductivity Trip Type 6

© 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 35
without prior permission of the copyright owner.
GEK 75512m Generator Protection

Protective Actions Key (i.e. Trip Types) for Table 2:

1. Simultaneous Trip

2. Generator Trip

3. Breaker Trip

4. Sequential Trip

5. Manual Trip

6. Manual Runback and Trip

7. Automatic Runback and Trip

8. Manual Runback

Table 2 does not purport to summarize all the descriptive material contained in the respective
sections. These must be read and understood when using this summary.

36 © 2012 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.
DWG Number GEK107538 Rev A Released 1/6/2014 Page 1 of 10

GEK107538A

g
January 2014

GE Power & Water

Basic Combined Cycle Start-up Procedure from a Turbine

Controls Point of View

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to General Electric
Company. These instructions contain proprietary information of General Electric Company, and are furnished to its customer solely
to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall
not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of General
Electric Company.
© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK107538 Rev A Released 1/6/2014 Page 2 of 10

GEK107538A Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View

The following notices will be found throughout this publication. It is important that the
significance of each is thoroughly understood by those using this document. The definitions are
as follows:

NOTE

Highlights an essential element of a procedure to ensure correctness

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER***

INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF

NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY

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without prior permission of the copyright owner.

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DWG Number GEK107538 Rev A Released 1/6/2014 Page 3 of 10

Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View GEK107538A

TABLE OF CONTENTS

I. GENERAL.................................................................................................................................4
A. Basic Points ..........................................................................................................................4
B. Basic Sequence of Operation.................................................................................................5
II. RELATED CONTROL SIGNALS ...........................................................................................8
A. From STC to DCS.................................................................................................................8
B. From DCS to STC.................................................................................................................8
C. From DCS to GTC................................................................................................................8
D. From GTC to DCS ................................................................................................................9

© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 3
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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK107538 Rev A Released 1/6/2014 Page 4 of 10

GEK107538A Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View

I. GENERAL

The intent of this publication is to identify typical design requirements and operating guidelines which
are needed to interface Steam Turbine and Gas Turbine controls with the DCS in a Combined Cycle
environment. This publication attempts to address customer’s concerns on “equipment only” (no
Combined Cycle Engineering by GE) contracts. These guidelines should be used taking into
consideration the many other Combined Cycle plant control requirements. This publication is written to
document all the information available from ST and GT Controls Engineering which would relate to
Combined Cycle control and operation. Additional information/engineering may be purchased from GE
Power Plant - Combined Cycle Engineering.

This publication addresses the methods utilized to limit stress on the steam turbine during startup in
combined cycle applications. Startup requirements of the steam generating equipment are not covered. It
is the station designer’s responsibility to address the limitations of all of the balance of plant equipment.

This publication is applicable to:

! Single- and multi-shaft ST and GT
! Cascading and parallel (non-cascading) ST bypass systems
! Single- and multi-HRSG steam systems

Additional details about turbine and turbine controls operation can be found in the Reference Documents.

A. Basic Points

1. The following is written with the assumption that the plant startup sequence contains some degree
of automation. Most of the automation is not required, and can be replaced by manual operator
commands. The automation that is described is done to help define the scope of control between
the various control systems.

2. While the GT control has a “BASE LOAD” selection available it should not be selected when the
unit is operated in combined cycle mode where the load and loading rate of the ST is affected by
changes in GT load.

3. HP bypass control valve, controlled by the DCS. Primary function is to control the pressure of the
HP header. This valve must be able to open in roughly four (4) seconds to keep the HP safety
valves from lifting in the event of a turbine trip or load rejection. This valve must also be capable
of rapid controllable position changes necessary for pressure control associated with changes in
turbine flow.

4. Hot Reheat (HRH) Bypass control valve (used with cascading bypass system), controlled by the
DCS. Primary function is to control the pressure in the reheater. This valve must also be capable
of rapid controllable position changes necessary for pressure control associated with changes in
turbine flow. This valve must be able to open in roughly four (4) seconds to keep the RH safety
valves from lifting in the event of a turbine trip or load rejection. The pressure setpoint of the
HRH bypass has a significant effect on ST operation. It affects the size of the step change in flow
that the HP turbine section sees when the turbine switches from reverse to forward flow, and it
affects the thrust loading of the turbine, due to unequal turbine section flows.

5. IP Drum pressure control: On a three-pressure reheat HRSG the IP drum/IP admission often feeds
steam to the cold reheat steam line (HP Turbine exhaust). The pressure in this line varies from

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DWG Number GEK107538 Rev A Released 1/6/2014 Page 5 of 10

Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View GEK107538A

less than 20% of rated, during a cold start, to 100% of rated during normal operation and can
change rapidly during transients. Steam production and velocity from this drum are a function of
pressure. A back pressure control valve in the line from the IP superheater to the CRH line is
required to stabilize the IP drum level and to provide an acceptable floor pressure for the IP drum
so that it does not produce too much steam at low reheat pressures.

6. A point that will only be briefly mentioned here is the need for over-temperature protection on
steam systems where an attemperator is used to control steam temperature. Over–temperature
protection must be incorporated in the system that controls the HRSG to prevent over-heating of
the HRSG and eventually the ST due to failure of the HRSG attemperation system. The GT
control system accepts three (3) signals from the HRSG control, Runback, Setback to Full Speed
No Load, and Trip.

B. Basic Sequence of Operation

1. Start the GT and bring it to “spinning reserve”/minimum load (5-10% load) and hold.

2. Warm up HRSG.

3. Read current ST metal (HP bowl for parallel bypass, RH bowl for cascading bypass) temperature
and determine appropriate startup steam temperature.

DCS continuously reads ST metal temperature, and latches in temperature at the time of steam
turbine start. The temperature must be latched prior to admitting steam to the turbine because the
shell temperature indication will change as steam is admitted and the temperature target should
not. Typical allowable steam to metal mismatch temperatures can be found in GEK 107034,
Recommended and Limit steam to metal temperature mismatches.

4. The DCS determines GT exhaust temperature that will produce necessary steam temperature. An
example algorithm: Exhaust temperature target = ST Metal Temperature + 250 DEGF, with a
lower limit of 700 DEGF and an upper limit of (Rated steam temperature + 50 DEGF). The HP
and LP exhaust temperatures are functions of steam flow, temperature, turbine speed, and the
pressures at the exhaust points. It may be necessary to reduce the upper limit of the exhaust
temperature target if the HP exhaust or LP exhaust temperatures exceed their limits during
startup.

5. DCS sends GT exhaust temperature target to GT turbine control, and turns “Temperature
Matching” ON.

Temperature target is not changed as the ST warms up.

If the temperature target is less than the current exhaust temperature, the GT will open its inlet
guide vanes to increase airflow and reduce exhaust temperature. If the target is greater than the
current exhaust temperature, the GT will leave the guide vanes at their minimum position and
increase fuel flow/power output to raise the exhaust temperature to meet the target.

Either way the operator may not change the GT load while temperature matching mode is “On”.

© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 5
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GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number GEK107538 Rev A Released 1/6/2014 Page 6 of 10

GEK107538A Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View

6. The DCS confirms acceptable steam temperature, pressure, and flow.

a. For FORWARD FLOW startup of the ST, Parallel Bypass system, where the ST is
accelerated by opening the HP stop/control valves, the minimum/maximum HP header
pressure is set by HRSG, and is not limited by ST. Hot Reheat pressure is initially near
condenser pressure, then proportional to load.

b. For REVERSE FLOW startup of the ST, Cascading Bypass system, Minimum pressure is
set by the HRSG/Bypass capacity. Maximum pressure is set by ST. The ”normal” limits for
the ST are: not more than 20% rated reheat pressure for a cold start and not more than 35%
or rated reheat pressure on a warm or hot start. Pressures greater than the limits will
generate excessive thermal stress during the transfer to forward flow and may generate
excessive thrust loads on the ST due to thrust imbalances between the HP and RH/IP
turbine sections.

c. Pressure prior to the ST transfer to Forward Flow mode. The bypasses may not be full
closed or full open. It is suggested that the HP and HRH bypass valves on ST roll-off pass
sufficient flow required for transfer to Forward Flow, which is 10% of rated mass flow
when reheat pressure is 20% of rated, and 16% when reheat pressure is 35%. C.

7. Initiate ST start (roll-off).

a. For units configured for Cascading Bypass the Reverse Flow Discharge Valve (RFDV) will
immediately open to evacuate the HP casing. Under certain conditions, the Reverse Flow
Valve (RFV) will open at 75% speed, admitting cold reheat steam to the HP ST exhaust.
This steam travels backwards through the HP turbine, exiting through the RFDV. This
steam flow keeps the latter stages of the HP section from overheating due to windage
heating. Both the RFV and the RFDV close when the control system transfers from “reverse
flow mode” to “forward flow mode”.

b. After synchronization select 100% as the ST load target.

8. The ST Intercept Valves perform speed and load control. Reheat pressure is controlled by the
reheat bypass valves.

The steam turbine controls adjust acceleration and loading based on turbine stresses. The ST
controls also predict an HP turbine stress for after transfer to Forward Flow. Very hot main steam
and/or a cold steam turbine can lead to transfer holds.

Transfer from Reverse to Forward flow will be conducted quickly for the ST, roughly 5 seconds.
During this short time the HP bypass valve pressure control must act quickly such that the main
steam pressure remains stable. If the HP bypass pressure control is set up with low gains and
large time constants, drum level problems will occur. Similar can be said for the HRH bypass
valve(s). The control of the IVs is dependent on stable reheat pressure. The IVs will open and
close rapidly in response to turbine control functions, and the HRH bypass valve must maintain
stable pressure.

Allow the ST to load in automatic until all steam produced is flowing through the ST. (HP Steam
Bypass at minimum control position)

9. Transfer the ST to Inlet pressure control

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DWG Number GEK107538 Rev A Released 1/6/2014 Page 7 of 10

Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View GEK107538A

10. When ST IN IPC feedback is received increase the bypass valve pressure setpoint to close the
HP bypass the rest of the way. When the HP bypass valves are closed and the ST is in Forward
Flow, the HP bypass pressure setpoint will track the actual main steam pressure with an offset.
When the IVs and reheat bypass valves are closed, the HRH pressure control setpoint will track
the natural hot reheat pressure, which is proportional to load, with an offset.

11. Turn GT “Temperature Matching” OFF. If the IGV’s were opened, they will reclose. If load
was raised to match the target it will not be returned to the original point. The load on the GT
may now be raised/ lowered by the operator/DCS.

12. Load the GT, limited by the ST Recommended Loading rate, to the desired plant load point.

The ST recommended loading rate is in %/minute, referring to percentage of rated ST load. The
normal range will be 0-10%/minute. The recommended loading rate is a function of ST stress,
rate of change of stress, differential expansion, and rate of change of differential expansion.
This rate is updated/changed several times per second, so it is GE’s feeling that it is not
practical to expect an operator to manually control the loading of the GT(s) to follow this rate.
We feel that the ST recommended loading should be automatically sent from the ST to the
DCS, where it is processed to control the loading of the GT(s).

If the combined cycle configuration is comprised of one GT and one ST then the assumption
can be made that a 1%/minute increase of GT load will result in a 3/4%/minute increase of ST
load. If the combined cycle configuration is two GT’s and one ST, and the load on one GT is
being held constant, then an increase of 2%/minute on the other GT will result in an increase of
3/4%/minute on the ST. If the load on both GT’s is increased at 1%/minute, then the output of
the ST will increase at 3/4%/minute. So, the DCS must transfer the ST loading rate to the
correct GT and factor in the number of GT’s that the load increase is being applied to. The
DCS must also recognize that steam turbine stress is also a strong function of steam
temperature ramp rate. Rated steam temperature is reached with the gas turbine at
approximately 30% load on GE GTs configured with DLN combustion.

13. Addition of subsequent units: When the plant configuration has more than one GT/HRSG
producing steam for a single ST, then provisions must be made to add steam from subsequent
GT/HRSGs to the operating ST. The following is a procedure for adding on a second unit with
a cascading bypass system.1.

Prior to opening any isolation valves:

a. The temperature of the steam from the “LAG” HRSG must be matched to that of the
“LEAD” HRSG by either using the GT temperature matching mode or raising/lowering the
“LAG” GT load.

b. The pressure of the LAG HP and RH headers must be perfectly matched to the LEAD HP
and RH header pressures by adjusting the LAG HP and HRH bypass setpoints.

c. The LEAD HP and HRH bypass valves should be in their normal operating mode, with
setpoints offset above the current pressure, and will change as the ST is loaded.

d. The LAG HRH bypass valve setpoint is a function of “Natural Pressure”. The LAG HP
bypass pressure setpoint will be manipulated to transfer steam to the ST.

© 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, 7
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DWG Number GEK107538 Rev A Released 1/6/2014 Page 8 of 10

GEK107538A Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View

e. Open the isolation valves in the order of Hot Reheat, Cold Reheat, HP. If all the pressures
were matched properly then there will be no change in flow(s) as the isolation valves are
opened.

f. The LAG HP bypass valve is slowly forced closed, transferring flow to the ST. The rate of
transfer should not exceed the ST recommended loading rate. Pressure in the HP header
will rise as flow is transferred to the ST.

g. As the HP header pressure rises, so will the calculated natural pressure and the LAG HRH
bypass pressure setpoint. As the LAG HRH bypass valve pressure setpoint rises the HRH
bypass valve will close, transferring flow to the RH turbine section.

h. When the LAG HP bypass fully closes its setpoint is set to current pressure plus an offset,
the same offset that is being use for the LEAD unit. At the same time the corresponding
bias for the LAG HRH is slowly added in to fully close it, if it wasn’t already closed.

The process for adding a second unit with a non-cascading bypass system is similar to that of
the cascading bypass system except that there is no control of steam flow through the reheater.

14. On a load rejection or a turbine trip, the inlet control valves and the IVs will be closed very
quickly (0.2-1.5 seconds). It may be necessary to pop the HP bypass valves open first in
approximately 2 seconds, then respond to the rising main steam pressure, to prevent opening of
the HRSG safety relief valves.

On a load rejection, the steam turbine configured for Cascading Bypass will transfer from
Forward Flow Mode back to Reverse Flow Mode.

II. RELATED CONTROL SIGNALS

A. From STC to DCS
ST Shell metal temperature: Used for temperature matching

Recommended Loading Rate: Used for loading the GT(s)

Speed/Load (TN_LD): Used in the calculation of natural pressure for HRH bypass pressure control

IN IPC: Indicates successful transfer to Inlet Pressure Control

B. From DCS to STC

Select IPC “IPC IN”: Initiates transfer to IPC

C. From DCS to GTC

Exhaust Temperature Target

Exhaust Temperature Ramp Rate: Rate that GT changes exhaust temperature when going into and
while in temperature matching mode

Temperature Matching ON: Turns temperature matching mode ON

Temperature Matching OFF: Turns temperature matching mode OFF

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without prior permission of the copyright owner.

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DWG Number GEK107538 Rev A Released 1/6/2014 Page 9 of 10

Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View GEK107538A

Either
Loading Rate Limit: Used to limit GT loading to a rate that is acceptable to the ST and BOP
Or

Load raise pushbutton: Used to manipulate GT load to produce a loading rate that is acceptable to the
ST and BOP.

Load lower pushbutton: Used to manipulate GT load to produce a loading rate that is acceptable to
the ST and BOP.

D. From GTC to DCS

GT Megawatts: Used as feedback when using raise and lower pushbuttons to control GT loading.

Reference Documents:

Steam Turbine and Controls:

GEK 107061 - Steam Turbine Guidelines for Multi–Shaft, Combined Cycle, Cascading Bypass Operation
GEK 107034 - Allowable Steam to Metal Temperature Mismatch
GEK 107170 – Control Description and Operation, Typical. ST bypass interface in Appendix
GEK 106671 – Thermal Stress Control.

Abbreviations Used:
DCS - Distributed Control System, Balance of plant controls, ST/GT/HRSG coordination controls
GT – Gas Turbine
HRSG – Heat Recovery Steam Generator
IGV – Inlet Guide Vanes
IV – ST Intercept Valve
ST – Steam Turbine
HP - High Pressure
LP - Low Pressure
HRH - Hot Reheat
STC - Steam Turbine Control
GTC - Gas Turbine Control

“Parallel Bypass” is a turbine bypass system where the HP steam bypasses directly to the condenser
through the HP bypass valve. Steam generated by the IP drum is either admitted to the cold reheat or
bypassed directly to the condenser. IP admission to the cold reheat is only allowed when the generator
breaker is closed. With this system there is no flow through the reheater when the turbine is not in
operation.

“Cascading Bypass” is a turbine bypass system where HP steam bypass is directed through HP bypass
valve into the cold reheat line. This steam then passes through the reheater. The Reheat steam bypasses
the RH and LP steam turbine through the HRH bypass, which exhausts to the condenser. Steam generated
in the IP drum is admitted to the cold reheat line, where it passes through the reheater and through the
same HRH bypass to the condenser. With this system the reheater is always passing the steam flow
produced by the HP evaporator, even when the turbine is not in operation.

“Natural Pressure” is the pressure that the reheater would be at if the HRH and HP bypasses were fully
closed and the IVs were full open. In other words, this would be the reheat pressure if the unit had a

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DWG Number GEK107538 Rev A Released 1/6/2014 Page 10 of 10

GEK107538A Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View

parallel (non–cascading) bypass system. “Natural pressure” used for control of the HRH bypass, is
calculated by the equation:

“Natural Pressure” = (Inlet Pressure /Rated Inlet Pressure) X “SPEED/LOAD” X Rated Reheat Pressure
Rated Inlet Pressure and Rated Reheat Pressure are constants.

Inlet Pressure is the current HP header pressure

“SPEED/LOAD” is the Steam Turbine Control speed/load control signal

g GE Power & Water

General Electric Company
www.gepower.com

10 © 2014 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part,
without prior permission of the copyright owner.

GE Proprietary Information - Class II (Internal) US EAR - NLR

GE Power and Water

Heavy-Duty Gas Turbine

Operating and Maintenance
Considerations
GER-3620M (05/14)

Jamison Janawitz

James Masso

Christopher Childs

GE Power and Water

Atlanta, GA
2
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Turbine Design Maintenance Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Borescope Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Major Factors Influencing Maintenance and Equipment Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starts and Hours Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Firing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steam/Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cyclic Effects and Fast Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hot Gas Path Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rotor Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Combustion Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Casing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust Diffuser Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Off-Frequency Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressor Condition and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lube Oil Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Moisture Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Standby Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Running Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rapid Cool-Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Combustion Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hot Gas Path Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Major Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Parts Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Borescope Inspection Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Combustion Inspection Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hot Gas Path Inspection Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rotor Inspection Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Personnel Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

GE Power & Water | GER-3620M (05/14) i

Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A.1) Example 1 – Hot Gas Path Maintenance Interval Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A.2) Example 2 – Hot Gas Path Factored Starts Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
B) Examples – Combustion Maintenance Interval Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
C) Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
D) Estimated Repair and Replacement Intervals (Natural Gas Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
E) Borescope Inspection Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
F) Turning Gear/Ratchet Running Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
G) B/E- and F-class Gas Turbine Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ii
Heavy-Duty Gas Turbine
Operating and Maintenance Considerations
Introduction repairs, and downtime. The primary factors that affect the
maintenance planning process are shown in Figure 1. The
Maintenance costs and machine availability are two of the most
owners’ operating mode and practices will determine how each
important concerns to a heavy-duty gas turbine equipment
factor is weighted. Gas turbine parts requiring the most careful
owner. Therefore, a well thought out maintenance program that
attention are those associated with the combustion process,
reduces the owner’s costs while increasing equipment availability
together with those exposed to the hot gases discharged from the
should be instituted. For this maintenance program to be effective,
combustion system. These are called the combustion section and
owners should develop a general understanding of the relationship
hot gas path parts, and they include combustion liners, end caps,
between the operating plans and priorities for the plant, the skill
fuel nozzle assemblies, crossfire tubes, transition pieces, turbine
level of operating and maintenance personnel, and all equipment
nozzles, turbine stationary shrouds, and turbine buckets.
manufacturer’s recommendations regarding the number and
types of inspections, spare parts planning, and other major factors Additional, longer-term areas for consideration and planning
affecting component life and proper operation of the equipment. are the lives of the compressor rotor, turbine rotor, casings, and
exhaust diffuser. The basic design and recommended maintenance
In this document, operating and maintenance practices for
of GE heavy-duty gas turbines are oriented toward:
heavy-duty gas turbines will be reviewed, with emphasis placed
on types of inspections plus operating factors that influence • Maximum periods of operation between inspections
maintenance schedules. and overhauls

Note: • In-place, on-site inspection and maintenance

• The operation and maintenance practices outlined in this • Use of local trade skills to disassemble, inspect, and re-assemble
document are based on full utilization of GE-approved parts, gas turbine components
repairs, and services. In addition to maintenance of the basic gas turbine, other station
• The operating and maintenance discussions presented auxiliaries require periodic servicing including the control devices,
are generally applicable to all GE heavy-duty gas turbines; fuel-metering equipment, gas turbine auxiliaries, and load package.
i.e., Frames 3, 5, 6, 7, and 9. Appendix G provides a list of common The primary maintenance effort involves five basic systems:
B/E- and F-class heavy-duty gas turbines with current and controls and accessories, combustion, turbine, generator, and
former naming conventions. For purposes of illustration, the balance-of-plant. Controls and accessories are typically serviced
GE GT-7E.03 was chosen for most components except exhaust in outages of short duration, whereas the other four systems are
systems, which are illustrated using different gas turbine models maintained through less frequent outages of longer duration.
as indicated. Also, the operating and maintenance discussions This document is focused on maintenance planning for the basic
presented for all B/E-class units are generally applicable to gas turbine, which includes the combustion and turbine systems.
Frame 3 and Frame 5 units unless otherwise indicated. The other systems, while outside the scope of this document, also
Consult the GE Operation and Maintenance (O&M) Manual need to be considered for successful plant maintenance.
for specific questions on a given machine, or contact the The inspection and repair requirements, outlined in the O&M
local GE service representative. Manual provided to each owner, lend themselves to establishing
a pattern of inspections. These inspection patterns will vary from
Maintenance Planning site to site, because factors such as air and fuel quality are used
Advanced planning for maintenance is necessary for utility, to develop an inspection and maintenance program. In addition,
industrial, independent power, and cogeneration plant operators supplementary information is provided through a system of
in order to maintain reliability and availability. The correct Technical Information Letters (TILs) associated with specific gas
implementation of planned maintenance and inspection provides turbines after shipment. This updated information, in addition
direct benefits in the avoidance of forced outages, unscheduled to the O&M Manual, assures optimum installation, operation,

GE Power & Water | GER-3620M (05/14) 1

 Manufacturer’s
Recommended Cost of
Design Features Duty Cycle
Maintenance Downtime
Program

Diagnostics &
Type of Fuel
Expert Systems
Maintenance
Planning Replacement
Reliability Need Parts
Availability/
Investment

On-Site Reserve
Maintenance Utilization Need Environment Requirements
Capability

Figure 1. Key factors affecting maintenance planning

and maintenance of the turbine. (See Figure 2.) Many of the TILs
Gas Turbine Design Maintenance
contain advisory technical recommendations to help resolve
Features
issues and improve the operation, maintenance, safety, reliability,
The GE heavy-duty gas turbine is designed to withstand severe
or availability of the turbine. The recommendations contained in
duty and to be maintained on-site, with off-site repair required
TILs should be reviewed and factored into the overall maintenance
only on certain combustion components, hot gas path parts, and
planning program.
rotor assemblies needing specialized shop service. The following
• O&M Manual features are designed into GE heavy-duty gas turbines to facilitate
– Turbine-specific manual provided to customer on-site maintenance:
– Includes outline of recommended Inspection and
• All casings, shells and frames are split on machine horizontal
Repair requirements
centerline. Upper halves may be lifted individually for access to
– Helps customers to establish a pattern of systematic
inspections for their site internal parts.

• Technical Information Letters (TILs)* • With upper-half compressor casings removed, all stationary

– Issued after shipment of turbine vanes can be slid circumferentially out of the casings for

– Provides O&M updates related to turbine installation, inspection or replacement without rotor removal.
maintenance, and operation
• With the upper-half of the turbine shell lifted, each half of the
– Provides advisory technical recommendations to help
first stage nozzle assembly can be removed for inspection,
resolve potential issues
repair, or replacement without rotor removal. On some units,
* Specific smaller frame turbines are issued service letters known as
Customer Information Notices (NICs) instead of TILs upper-half, later-stage nozzle assemblies are lifted with the
turbine shell, also allowing inspection and/or removal of
Figure 2. Key technical reference documents to include in maintenance
the turbine buckets.
planning

2
• All turbine buckets are moment-weighed and computer charted Provisions have been built into GE heavy-duty gas turbines to
in sets for rotor spool assembly so that they may be replaced facilitate several special inspection procedures. These special
without the need to remove or rebalance the rotor assembly. procedures provide for the visual inspection and clearance
measurement of some of the critical internal components
• All bearing housings and liners are split on the horizontal
without removal of the casings. These procedures include gas
centerline so that they may be inspected and replaced when
path borescope inspection (BI), radial clearance measurements,
necessary. The lower half of the bearing liner can be removed
and turbine nozzle axial clearance measurements.
without removing the rotor.
A GE gas turbine is a fully integrated design consisting of stationary
• All seals and shaft packings are separate from the main
and rotating mechanical, fluid, thermal, and electrical systems.
bearing housings and casing structures and may be readily
The turbine’s performance, as well as the performance of each
removed and replaced.
component within the turbine, is dependent upon the operating
• On most designs, fuel nozzles, combustion liners and flow interrelationship between internal components and the total
sleeves can be removed for inspection, maintenance, or operating systems. GE’s engineering process evaluates how new
replacement without lifting any casings. All major accessories, designs, design changes, and repairs affect components and
including filters and coolers, are separate assemblies that are systems. This design, evaluation, testing, and approval assures
readily accessible for inspection or maintenance. They may the proper balance and interaction between all components and
also be individually replaced as necessary. systems for safe, reliable, and economical operation.
• Casings can be inspected during any outage or any shutdown The introduction of new, repaired, or modified parts must be
when the unit enclosure is cool enough for safe entry. The evaluated in order to avoid negative effects on the operation
exterior of the inlet, compressor case, compressor discharge and reliability of the entire system. The use of non-GE approved
case, turbine case, and exhaust frame can be inspected during parts, repairs, and maintenance practices may represent a
any outage or period when the enclosure is accessible. The significant risk. Pursuant to the governing terms and conditions,
interior surfaces of these cases can be inspected to various warranties and performance guarantees are predicated upon
degrees depending on the type of outage performed. All interior proper storage, installation, operation, and maintenance,
surfaces can be inspected during a major outage when the rotor conforming to GE approved operating instruction manuals
has been removed. and repair/modification procedures.
• Exhaust diffusers can be inspected during any outage by
Borescope Inspections
entering the diffuser through the stack or Heat Recovery
An effective borescope inspection program monitors the condition
Steam Generator (HRSG) access doors. The flow path surfaces,
of internal components without casing removal. Borescope
flex seals, and other flow path hardware can be visually
inspections should be scheduled with consideration given to the
inspected with or without the use of a borescope. Diffusers
operation and environment of the gas turbine and information
can be weld-repaired without the need to remove the exhaust
from the O&M Manual and TILs.
frame upper half.
GE heavy-duty gas turbine designs incorporate provisions in
• Inlets can be inspected during any outage or shutdown.
both compressor and turbine casings for borescope inspection
As an alternative to on-site maintenance, in some cases plant of intermediate compressor rotor stages, first, second and third-
availability can be improved by applying gas turbine modular stage turbine buckets, and turbine nozzle partitions. These
replacements. This is accomplished by exchanging engine modules provisions are radially aligned holes through the compressor
or even the complete gas turbine with new or refurbished units. casings, turbine shell, and internal stationary turbine shrouds
The removed modules/engines can then be sent to an alternate that allow the penetration of an optical borescope into the
location for maintenance. compressor or turbine flow path area, as shown in Figure 3.

GE Power & Water | GER-3620M (05/14) 3

 1st Nozzle TE 1st Bucket TE 2nd Nozzle TE 2nd Bucket TE 3rd Nozzle TE
1st Bucket LE 2nd Nozzle LE 2nd Bucket LE 3rd Nozzle LE 3rd Bucket LE

32º 34º 42º 34º 42º

18º Compressor-17th Stage

Primary Inspection Access
18º (Normal Inspection)
Compressor-12th Stage
Secondary Inspection Access
(Additional Stators & Nozzles)
18º
Compressor-4th Stage Access for Eddy-current
& Nozzle Deflection Inspection

Legend
LE = Leading Edge
TE = Trailling Edge

Figure 3. 7E.03 gas turbine borescope inspection access locations

Borescope inspection access locations for F-class gas turbines

Gas and
can be found in Appendix E. At combustion inspection or annually,
Distillate
whichever occurs first
Figure 4 provides a recommended interval for a planned Fuel Oil
Borescope
borescope inspection program following initial baseline Heavy At combustion inspection or
inspections. It should be recognized that these borescope Fuel Oil semiannually, whichever occurs first
inspection intervals are based on average unit operating modes.
Figure 4. Borescope inspection planning
Adjustment of these borescope intervals may be made based
on operating experience, mode of operation, fuels used, and the During BIs and similar inspections, the condition of the upstream

results of previous borescope inspections. components should be verified, including all systems from the filter
house to the compressor inlet.
In general, an annual or semiannual borescope inspection uses
all the available access points to verify the condition of the The application of a borescope monitoring program will assist with

internal hardware. This should include, but is not limited to, signs the scheduling of outages and preplanning of parts requirements,

of excessive gas path fouling, symptoms of surface degradation resulting in outage preparedness, lower maintenance costs, and

(such as erosion, corrosion, or spalling), displaced components, higher availability and reliability of the gas turbine.

deformation or object damage, material loss, nicks, dents, cracking,

indications of contact or rubbing, or other anomalous conditions.

4
Major Factors Influencing selected such that components acceptable for continued use
at the inspection point will have low risk of failure during the
Maintenance and Equipment Life
subsequent operating interval.
There are many factors that can influence equipment life,
and these must be understood and accounted for in the • Continuous Duty Application • Cyclic Duty Application
owner’s maintenance planning. Starting cycle (hours per start), – Rupture – Thermal Mechanical
– Creep Deflection Fatigue
power setting, fuel, level of steam or water injection, and
– Corrosion – High-Cycle Fatigue
site environmental conditions are some of the key factors in
– Oxidation – Rubs/Wear
determining maintenance interval requirements, as these factors
– Erosion – Foreign Object Damage
directly influence the life of replaceable gas turbine parts.
– High-Cycle Fatigue
Non-consumable components and systems, such as the – Rubs/Wear
compressor airfoils, may be affected by site environmental – Foreign Object Damage
conditions as well as plant and accessory system effects. Other
Figure 5. Causes of wear – hot gas path components
factors affecting maintenance planning are shown in Figure 1.
Operators should consider these external factors to prevent the An alternative to the GE approach, which is sometimes employed
degradation and shortened life of non-consumable components. by other manufacturers, converts each start cycle to an equivalent
GE provides supplementary documentation to assist in this regard. number of operating hours (EOH) with inspection intervals based
on the equivalent hours count. For the reasons previously stated,
In the GE approach to maintenance planning, a natural gas fuel
GE does not use this approach. While this logic can create the
unit that operates at base load with no water or steam injection
impression of longer intervals, it actually may result in more
is established as the baseline condition, which sets the maximum
frequent maintenance inspections, since separate effects are
recommended maintenance intervals. For operation that differs
considered additive. Referring again to Figure 6, the starts and
from the baseline, maintenance factors (MF) are established to
hours inspection “rectangle” is reduced by half as defined by the
quantify the effect on component lives and provide the increased
diagonal line from the starts limit at the upper left hand corner
frequency of maintenance required. For example, a maintenance
to the hours limit at the lower right hand corner. Midrange duty
factor of two would indicate a maintenance interval that is half of
applications, with hours-per-start ratios of 30-50, are particularly
the baseline interval.
penalized by this approach.
Starts and Hours Criteria This is further illustrated in Figure 7 for the example of a 7E.03
Gas turbines wear differently in continuous duty application and gas turbine operating on natural gas fuel, at base load conditions
cyclic duty application, as shown in Figure 5. Thermal mechanical with no steam or water injection or trips from load. The unit
fatigue is the dominant life limiter for peaking machines, while operates 4000 hours and 300 starts per year. Following GE’s
creep, oxidation, and corrosion are the dominant life limiters for recommendations, the operator would perform the hot gas path
continuous duty machines. Interactions of these mechanisms inspection after four years of operation, with starts being the
are considered in the GE design criteria but to a great extent limiting condition. Performing maintenance on this same unit
are second-order effects. For that reason, GE bases gas turbine based on an equivalent hours criteria would require a hot gas
maintenance requirements on independent counts of starts and path inspection after 2.4 years. Similarly, for a continuous duty
hours. Whichever criteria limit is first reached determines the application operating 8000 hours and 160 starts per year, the
maintenance interval. A graphical display of the GE approach GE recommendation would be to perform the hot gas path
is shown in Figure 6. In this figure, the inspection interval inspection after three years of operation with the operating
recommendation is defined by the rectangle established hours being the limiting condition for this case. The equivalent
by the starts and hours criteria. These recommendations hours criteria would set the hot gas path inspection after
for inspection fall within the design life expectations and are 2.1 years of operation for this application.

GE Power & Water | GER-3620M (05/14) 5

 uou s
Contin
Unit

Figure 6. GE bases gas turbine maintenance requirements on independent counts of starts and hours

GE vs. Equivalent Operating Hours (EOH) Approach

1400
Case 1
1200 4,000 Hrs/Yr
300 Starts/Yr
1000 GE Every 4 Yr
GE Method
EOH Every 2.4 Yr
800
Starts

600 Case 2
8,000 Hrs/Yr
400 160 Starts/Yr
GE Every 3 Yr
200
EOH Every 2.1 Yr
0
0 4 8 12 16 20 24 28
Thousands of Fired Hours
Figure 7. Hot gas path maintenance interval comparisons. GE method vs. EOH method

6
Service Factors When these service or maintenance factors are involved in a unit’s
While GE does not subscribe to the equivalency of starts to hours, operating profile, the hot gas path maintenance “rectangle” that
there are equivalencies within a wear mechanism that must be describes the specific maintenance criteria for this operation is
considered. As shown in Figure 8, influences such as fuel type and reduced from the ideal case, as illustrated in Figure 9. The following
quality, firing temperature setting, and the amount of steam or discussion will take a closer look at the key operating factors
water injection are considered with regard to the hours-based and how they can affect maintenance intervals as well as parts
criteria. Startup rate and the number of trips are considered with refurbishment/replacement intervals.
regard to the starts-based criteria. In both cases, these influences
Maintenance Factors Reduce Maintenance Interval
may reduce the maintenance intervals. 1,400

1,200
Starts-Based Factors
Typical baseline inspection intervals (6B.03/7E.03): 1,000 • Start type
• Start load
Hot gas path inspection 24,000 hrs or 1200 starts

Starts
800 • Trips

Major inspection 48,000 hrs or 2400 starts 600

Hours-Based Factors
Criterion is hours or starts (whichever occurs first) 400 • Fuel type
• Peak load
Factors affecting maintenance: 200 • Diluent

Hours-Based Factors 0
0 4 8 12 16 20 24 28
• Fuel type
Thousands of Fired Hours
• Peak load Figure 9. GE maintenance intervals
• Diluent (water or steam injection)
Starts-Based Factors Fuel
• Start type (conventional or peaking-fast) Fuels burned in gas turbines range from clean natural gas to
• Start load (max. load achieved during start cycle, e.g. residual oils and affect maintenance, as illustrated in Figure 10.
part, base, or peak load) Although Figure 10 provides the basic relationship between fuel
• Trips severity factor and hydrogen content of the fuel, there are other
fuel constituents that should be considered. Selection of fuel
Figure 8. Maintenance factors
Increasing Fuel Severity Factor

Residual
Distillates

Heavy Light Natural Gas

Increasing Hydrogen Content in Fuel

Figure 10. Estimated effect of fuel type on maintenance

GE Power & Water | GER-3620M (05/14) 7

severity factor typically requires a comprehensive understanding As shown in Figure 10, natural gas fuel that meets GE specification
of fuel constituents and how they affect system maintenance. is considered the baseline, optimum fuel with regard to turbine
The selected fuel severity factor should also be adjusted based maintenance. Proper adherence to GE fuel specifications in
on inspection results and operating experience. GEI-41040 and GEI-41047 is required to allow proper combustion
system operation and to maintain applicable warranties. Liquid
Heavier hydrocarbon fuels have a maintenance factor ranging
hydrocarbon carryover can expose the hot gas path hardware to
from three to four for residual fuels and two to three for crude
severe overtemperature conditions that can result in significant
oil fuels. This maintenance factor is adjusted based on the
reductions in hot gas path parts lives or repair intervals.
water-to-fuel ratio in cases when water injection for NOx
Liquid hydrocarbon carryover is also responsible for upstream
abatement is used. These fuels generally release a higher
displacement of flame in combustion chambers, which can lead
amount of radiant thermal energy, which results in a subsequent
to severe combustion hardware damage. Owners can control
reduction in combustion hardware life, and frequently contain
this potential issue by using effective gas scrubber systems and
corrosive elements such as sodium, potassium, vanadium, and
by superheating the gaseous fuel prior to use to approximately
lead that can cause accelerated hot corrosion of turbine nozzles
50°F (28°C) above the hydrocarbon dew point temperature at
and buckets. In addition, some elements in these fuels can
the turbine gas control valve connection. For exact superheat
cause deposits either directly or through compounds formed
requirement calculations, please review GEI 41040. Integral to the
with inhibitors that are used to prevent corrosion. These
system, coalescing filters installed upstream of the performance
deposits affect performance and can require more frequent
gas heaters is a best practice and ensures the most efficient
maintenance.
removal of liquids and vapor phase constituents.
Distillates, as refined, do not generally contain high levels of
Undetected and untreated, a single shipment of contaminated
these corrosive elements, but harmful contaminants can be
fuel can cause substantial damage to the gas turbine hot gas
present in these fuels when delivered to the site. Two common
path components. Potentially high maintenance costs and loss
ways of contaminating number two distillate fuel oil are: salt-
of availability can be minimized or eliminated by:
water ballast mixing with the cargo during sea transport, and
contamination of the distillate fuel when transported to site in • Placing a proper fuel specification on the fuel supplier.
tankers, tank trucks, or pipelines that were previously used to For liquid fuels, each shipment should include a report that
transport contaminated fuel, chemicals, or leaded gasoline. GE’s identifies specific gravity, flash point, viscosity, sulfur content,
experience with distillate fuels indicates that the hot gas path pour point and ash content of the fuel.
maintenance factor can range from as low as one (equivalent
• Providing a regular fuel quality sampling and analysis program.
to natural gas) to as high as three. Unless operating experience
As part of this program, continuous monitoring of water
suggests otherwise, it is recommended that a hot gas path
content in fuel oil is recommended, as is fuel analysis that,
maintenance factor of 1.5 be used for operation on distillate oil.
at a minimum, monitors vanadium, lead, sodium, potassium,
Note also that contaminants in liquid fuels can affect the life
calcium, and magnesium.
of gas turbine auxiliary components such as fuel pumps and
flow dividers. • Providing proper maintenance of the fuel treatment system
when burning heavier fuel oils.
Not shown in Figure 10 are alternative fuels such as industrial
process gas, syngas, and bio-fuel. A wide variety of alternative • Providing cleanup equipment for distillate fuels when there

fuels exist, each with their own considerations for combustion in is a potential for contamination.

a gas turbine. Although some alternative fuels can have a neutral In addition to their presence in the fuel, contaminants can
effect on gas turbine maintenance, many alternative fuels require also enter the turbine via inlet air, steam/water injection, and
unit-specific intervals and fuel severity factors to account for their carryover from evaporative coolers. In some cases, these
fuel constituents or water/steam injection requirements. sources of contaminants have been found to cause hot gas path

8
degradation equal to that seen with fuel-related contaminants. heat recovery applications, where steam generation drives overall
GE specifications define limits for maximum concentrations of plant efficiency, load is first reduced by closing variable inlet
contaminants for fuel, air, and steam/water. guide vanes to reduce inlet airflow while maintaining maximum
exhaust temperature. For these combined cycle applications,
In addition to fuel quality, fuel system operation is also a factor in
firing temperature does not decrease until load is reduced below
equipment maintenance. Liquid fuel should not remain unpurged
approximately 80% of rated output. Conversely, a non-DLN turbine
or in contact with hot combustion components after shutdown
running in simple cycle mode maintains fully open inlet guide
and should not be allowed to stagnate in the fuel system when
vanes during a load reduction to 80% and will experience over a
strictly gas fuel is run for an extended time. To minimize varnish
200°F/111°C reduction in firing temperature at this output level.
and coke accumulation, dual fuel units (gas and liquid capable)
The hot gas path parts life changes for different modes of
should be shutdown running gas fuel whenever possible. Likewise,
operation. This turbine control effect is illustrated in Figure 12.
during extended operation on gas, regular transfers from gas to
Turbines with DLN combustion systems use inlet guide vane
liquid are recommended to exercise the system components and
turndown as well as inlet bleed heat to extend operation of
minimize coking.
low NOx premix operation to part load conditions.
Contamination and build-up may prevent the system from
Firing 2500
removing fuel oil and other liquids from the combustion, B/E-class
Temp.
compressor discharge, turbine, and exhaust sections when IGVs close max to min
1200 at constant TF
the unit is shut down or during startup. Liquid fuel oil trapped
2000
in the system piping also creates a safety risk. Correct functioning Min IGV
1000
of the false start drain system (FSDS) should be ensured through °F Max IGV (open)
°C
proper maintenance and inspection per GE procedures. 800 1500 Heat Recovery
IGVs close max to min Simple Cycle
Base Load
Firing Temperatures at constant TX
Peak Load
600
Peak load is defined as operation above base load and is 1000
20 40 60 80 100 120
achieved by increasing turbine operating temperatures.
% Load
Significant operation at peak load will require more frequent
Figure 12. Firing temperature and load relationship – heat recovery vs. simple
maintenance and replacement of hot gas path and combustion cycle operation
components. Figure 11 defines the parts life effect corresponding
to increases in firing temperature. It should be noted that this is Firing temperature effects on hot gas path maintenance, as
not a linear relationship, and this equation should not be used for described above, relate to clean burning fuels, such as natural
decreases in firing temperature. gas and light distillates, where creep rupture of hot gas path
components is the primary life limiter and is the mechanism
It is important to recognize that a reduction in load does not
that determines the hot gas path maintenance interval impact.
always mean a reduction in firing temperature. For example, in
With ash-bearing heavy fuels, corrosion and deposits are
the primary influence and a different relationship with firing
temperature exists.
B/E-class: Ap = e (0.018*ΔTf )

F-class: Ap = e (0.023*ΔTf ) Steam/Water Injection

Water or steam injection for emissions control or power
Ap = Peak fire severity factor augmentation can affect part life and maintenance intervals
ΔTf = Peak firing temperature adder (in °F) even when the water or steam meets GE specifications. This
relates to the effect of the added water on the hot gas transport
properties. Higher gas conductivity, in particular, increases the
Figure 11. Peak fire severity factors - natural gas and light distillates

GE Power & Water | GER-3620M (05/14) 9

heat transfer to the buckets and nozzles and can lead to higher Water injection for NOx abatement should be performed according
metal temperature and reduced part life. to the control schedule implemented in the controls system.
Forcing operation of the water injection system at high loads
Part life reduction from steam or water injection is directly
can lead to combustion and HGP hardware damage due to
affected by the way the turbine is controlled. The control system
thermal shock.
on most base load applications reduces firing temperature as
water or steam is injected. This is known as dry control curve
Cyclic Effects and Fast Starts
operation, which counters the effect of the higher heat transfer
In the previous discussion, operating factors that affect the
on the gas side and results in no net effect on bucket life. This
hours-based maintenance criteria were described. For the
is the standard configuration for all gas turbines, both with and
starts-based maintenance criteria, operating factors associated
without water or steam injection. On some installations, however,
with the cyclic effects induced during startup, operation, and
the control system is designed to keep firing temperature constant
shutdown of the turbine must be considered. Operating conditions
with water or steam injection. This is known as wet control curve
other than the standard startup and shutdown sequence can
operation, which results in additional unit output but decreases
potentially reduce the cyclic life of the gas turbine components
parts life as previously described. Units controlled in this way
and may require more frequent maintenance including part
are generally in peaking applications where annual operating
refurbishment and/or replacement.
hours are low or where operators have determined that reduced
parts lives are justified by the power advantage. Figure 13 Fast starts are common deviations from the standard startup

illustrates the wet and dry control curve and the performance sequence. GE has introduced a number of different fast start

differences that result from these two different modes of control. systems, each applicable to particular gas turbine models. Fast
starts may include any combination of Anticipated Start Purge,
An additional factor associated with water or steam injection
fast acceleration (light-off to FSNL), and fast loading. Some fast
relates to the higher aerodynamic loading on the turbine
start methods do not affect inspection interval maintenance
components that results from the injected flow increasing the
factors. Fast starts that do affect maintenance factors are
cycle pressure ratio. This additional loading can increase the
referred to as peaking-fast starts or simply peaking starts.
downstream deflection rate of the second- and third-stage nozzles,
which would reduce the repair interval for these components. The effect of peaking-fast starts on the maintenance interval

However, the introduction of high creep strength stage two and depends on the gas turbine model, the unit configuration, and

three nozzle (S2N/S3N) alloys, such as GTD-222™ and GTD-241™, the particular start characteristics. For example, simple cycle

has reduced this factor in comparison to previously applied 7F.03 units with fast start capability can perform a peaking start

materials such as FSX-414 and N-155. in which the unit is brought from light-off to full load in less than
15 minutes. Conversely, simple cycle 6B and other smaller frame
units can perform conventional starts that are less than 15
Steam Injection for 25 pmm NOx
minutes without affecting any maintenance factors. For units
3% Steam Inj. that have peaking-fast start capability, Figure 14 shows
Exhaust Temperature °F

TF = 2020°F (1104°C)
Wet Control
Load Ratio = 1.10
conservative peaking-start factors that may apply.
Dry Control
Because the peaking-fast start factors can vary by unit and
0% Steam Inj. by system, the baseline factors may not apply to all units. For
TF = 2020°F (1104°C) example, the latest 7F.03 peaking-fast start system has the start
Load Ratio = 1.0 3% Steam Inj.
TF = 1994°F (1090°C) factors shown in Figure 15. For comparison, the 7F.03 nominal
Load Ratio = 1.08
The Wet Control Curve fast start that does not affect maintenance is also listed. Consult
Maintains Constant TF applicable unit-specific documentation or your GE service
representative to verify the start factors that apply.
Compressor Discharge Pressure (psig)
Figure 13. Exhaust temperature control curve – dry vs. wet control 7E.03

10
 Base Load

Starts-Based Combustion Inspection

As = 4.0 for B/E-class Light-Off Unload Ramp
As = 2.0 for F-class

Temperature
Acceleration
Load Ramp

Starts-Based Hot Gas Path Inspection Full Speed

No Load
Ps = 3.5 for B/E-class Full Speed
Warm-Up No Load Fired Shutdown
Ps = 1.2 for F-class
Trip
Starts-Based Rotor Inspection
Fs = 2.0 for F-class* Startup Shutdown
Time
* See Figure 22 for details
Figure 16. Turbine start/stop cycle – firing temperature changes

Figure 14. Peaking-fast start factors

Cold

7F.03 Starts-Based Combustion Inspection

As = 1.0 for 7F nominal fast start
As = 1.0 for 7F peaking-fast start

7F.03 Starts-Based Hot Gas Path Inspection

Ps = Not applicable for 7F nominal fast start
(counted as normal starts)
Ps = 0.5 for 7F peaking-fast start

7F.03 Starts-Based Rotor Inspection Hot

Fs = 1.0 for 7F nominal fast start
Fs = 2.0 for 7F peaking-fast start* Figure 17. Second stage bucket transient temperature distribution

* See Figure 23 for details

in the bucket as the fast responding leading edge heats up more
quickly than the thicker bulk section of the airfoil. At full load
Figure 15. 7F.03 fast start factors
conditions, the bucket reaches its maximum metal temperature

Hot Gas Path Parts and a compressive strain is produced from the normal steady

Figure 16 illustrates the firing temperature changes occurring state temperature gradients that exist in the cooled part. At

over a normal startup and shutdown cycle. Light-off, acceleration, shutdown, the conditions reverse and the faster responding

loading, unloading, and shutdown all produce gas and metal edges cool more quickly than the bulk section, which results

temperature changes. For rapid changes in gas temperature, in a tensile strain at the leading edge.

the edges of the bucket or nozzle respond more quickly than Thermal mechanical fatigue testing has found that the number
the thicker bulk section, as pictured in Figure 17. These gradients, of cycles that a part can withstand before cracking occurs is
in turn, produce thermal stresses that, when cycled, can eventually strongly influenced by the total strain range and the maximum
lead to cracking. metal temperature. Any operating condition that significantly

Figure 18 describes the temperature/strain history of a 7E.03 increases the strain range and/or the maximum metal temperature

stage 1 bucket during a normal startup and shutdown cycle. over the normal cycle conditions will reduce the fatigue life and

Light-off and acceleration produce transient compressive strains increase the starts-based maintenance factor. For example,

GE Power & Water | GER-3620M (05/14) 11

Figure 19 compares a normal operating cycle with one that temperatures at the initiation of the trip event. Figure 20
includes a trip from full load. The significant increase in the illustrates that while a trip from between 80% and 100% load
strain range for a trip cycle results in a life effect that equates has an 8:1 trip severity factor, a trip from full speed no load (FSNL)
to eight normal start/stop cycles, as shown. Trips from part has a trip severity factor of 2:1. Similarly, overfiring of the unit
load will have a reduced effect because of the lower metal during peak load operation leads to increased component

Key Parameters
• Max Strain Range
Fired
• Max Metal Temperature Shutdown

FSNL

TMAX
% Strain

0
Metal Temperature

∆ε Base Load
MAX

Acceleration
Light Off
& Warm-up

Figure 18. Bucket low cycle fatigue (LCF)

Leading Edge Temperature/Strain

Normal Startup/Shutdown Normal Start & Trip

+ +
T T
MAX MAX
Strain Strain
~% Temperature
Temp
Temper
erat
atur
ure
e ~% Temperature
∆ε ∆ε
MAX
MAX MAX
- -

1 Trip Cycle = 8 Normal Shutdown Cycles

Figure 19. Low cycle fatigue life sensitivities – first stage bucket

12
 10 1.4

Base 1.2
8 F-class and

Maintenance Factor
B/E-class Units with 1.0
aT – Trip Severity Factor

Inlet Bleed Heat

6 0.8
Units without
Inlet Bleed Heat 0.6
4
0.4
Note:
2 • For Trips During Startup Accel Assume aT=2 0.2
FSNL
• For Trips from Peal Load Assume aT=2
0.0
0 0 20 40 60 80 100
0 20 40 60 80 100 % Load
% Load
Figure 21. Maintenance factor – effect of start cycle maximum load level
Figure 20. Maintenance factor – trips from load

Factored starts calculations are based upon the maximum load

metal temperatures. As a result, a trip from peak load has
achieved during operation. Therefore, if a unit is operated at part
a trip severity factor of 10:1.
load for three weeks, and then ramped up to base load for the last
Trips are to be assessed in addition to the regular startup/shutdown ten minutes, then the unit’s total operation would be described as a
cycles as starts adders. As such, in the factored starts equation base load start/stop cycle.
of Figure 43, one is subtracted from the severity factor so that the
net result of the formula (Figure 43) is the same as that dictated Rotor Parts
by the increased strain range. For example, a startup and trip The maintenance and refurbishment requirements of the rotor

from base load would count as eight total cycles (one cycle for structure, like the hot gas path components, are affected by

startup to base load plus 8-1=7 cycles for trip from base load), the cyclic effects of startup, operation, and shutdown, as well as

just as indicated by the 8:1 maintenance factor. loading and off-load characteristics. Maintenance factors specific
to the operating profile and rotor design must be incorporated into
Similarly to trips from load, peaking-fast starts will affect the
the operator’s maintenance planning. Disassembly and inspection
starts-based maintenance interval. Like trips, the effects of
of all rotor components is required when the accumulated rotor
a peaking-fast start on the machine are considered separate
starts or hours reach the inspection limit. (See Figure 44 and
from a normal cycle and their effects must be tabulated in
Figure 45 in the Inspection Intervals section.)
addition to the normal start/stop cycle. However, there is no
-1 applied to these factors, so a 7F.03 peaking-fast start during The thermal condition when the startup sequence is initiated

a base load cycle would have a total effect of 1.5 cycles. is a major factor in determining the rotor maintenance interval

Refer to Appendix A for factored starts examples, and consult and individual rotor component life. Rotors that are cold when

unit-specific documentation to determine if an alternative the startup commences experience transient thermal stresses

hot gas path peaking-fast start factor applies. as the turbine is brought on line. Large rotors with their longer
thermal time constants develop higher thermal stresses than
While the factors described above will decrease the starts-based
smaller rotors undergoing the same startup time sequence. High
maintenance interval, part load operating cycles allow for an
thermal stresses reduce thermal mechanical fatigue life and the
extension of the maintenance interval. Figure 21 can be used in
inspection interval.
considering this type of operation. For example, two operating
cycles to maximum load levels of less than 60% would equate Though the concept of rotor maintenance factors is applicable

to one start to a load greater than 60% or, stated another way, to all gas turbine rotors, only F-class rotors will be discussed in

would have a maintenance factor of 0.5. detail. For all other rotors, reference unit-specific documentation
to determine additional maintenance factors that may apply.

GE Power & Water | GER-3620M (05/14) 13

The rotor maintenance factor for a startup is a function of the The significance of each of these factors is dependent on the unit
downtime following a previous period of operation. As downtime operation. There are three categories of operation that are typical
increases, the rotor metal temperature approaches ambient of most gas turbine applications. These are peaking, cyclic, and
conditions, and thermal fatigue during a subsequent startup continuous duty as described below:
increases. As such, cold starts are assigned a rotor maintenance
• Peaking units have a relatively high starting frequency and a low
factor of two and hot starts a rotor maintenance factor of less
number of hours per start. Operation follows a seasonal demand.
than one due to the lower thermal stress under hot conditions.
Peaking units will generally see a high percentage of warm and
This effect varies from one location in the rotor structure to
cold starts.
another. The most limiting location determines the overall rotor
maintenance factor. • Cyclic units start daily with weekend shutdowns. Twelve to
sixteen hours per start is typical, which results in a warm rotor
Initial rotor thermal condition is not the only operating factor
condition for a large percentage of the starts. Cold starts are
that influences rotor maintenance intervals and component
generally seen only after a maintenance outage or following a
life. Peaking-fast starts, where the turbine is ramped quickly
two-day weekend outage.
to load, increase thermal gradients on the rotor. Trips from
load, particularly trips followed by immediate restarts, and hot • Continuous duty applications see a high number of hours

restarts reduce the rotor maintenance interval. Figure 22 lists per start. Most starts are cold because outages are generally

recommended operating factors that should be used to determine maintenance driven. While the percentage of cold starts is high,

the rotor’s overall maintenance factor for certain F-class rotors. the total number of starts is low. The rotor maintenance interval
on continuous duty units will be determined by operating hours
F-class* Rotors rather than starts.

Rotor Maintenance Factors Figure 23 lists operating profiles on the high end of each of
these three general categories of gas turbine applications. These
Peaking-Fast Normal
Start** Start duty cycles have different combinations of hot, warm, and cold
starts with each starting condition having a different effect on
Hot 1 Start Factor
4.0 2.0 rotor maintenance interval as previously discussed. As a result,
(0–1 Hr. Down)
the starts-based rotor maintenance interval will depend on an
Hot 2 Start Factor
1.0 0.5 application’s specific duty cycle. In the Rotor Inspection Interval
(1–4 Hrs. Down)
section, a method will be described to determine a maintenance
Warm 1 Start Factor
1.8 0.9 factor that is specific to the operation’s duty cycle. The application’s
(4–20 Hrs. Down)
integrated maintenance factor uses the rotor maintenance factors
Warm 2 Start Factor
2.8 1.4 described above in combination with the actual duty cycle of a
(20–40 Hrs. Down)
specific application and can be used to determine rotor inspection
Cold Start Factor intervals. In this calculation, the reference duty cycle that yields
4.0 2.0
(>40 Hrs. Down)
a starts-based maintenance factor equal to one is defined in

Trip from Load Factor 4.0 4.0 Figure 24. Duty cycles different from the Figure 24 definition,
in particular duty cycles with more cold starts or a high number
*Other factors may apply to early 9F.03 units of trips, will have a maintenance factor greater than one.
**An F-class peaking-fast start is typically a start in which the
Turning gear or ratchet operation after shutdown and before
unit is brought from light-off to full load in less than 15 minutes.
starting/restarting is a crucial part of normal operating procedure.
Figure 22. Operation-related maintenance factors
After a shutdown, turning of the warm rotor is essential to avoid
bow, or bend, in the rotor. Initiating a start with the rotor in a

14
 bowed condition could lead to high vibrations and excessive rubs.
Peaking Cyclic Continuous
Figure F-1 describes turning gear/ratchet scenarios and operation
Hot 2 Start
3% 1% 10% guidelines (See Appendix). Relevant operating instructions and
(Down 1-4 Hr.)
TILs should be adhered to where applicable. As a best practice,
Warm 1 Start
10% 82% 5% units should remain on turning gear or ratchet following a planned
(Down 4-20 hr.)
shutdown until wheelspace temperatures have stabilized at or
Warm 2 Start
37% 13% 5% near ambient temperature. If the unit is to see no further activity
(Down 20-40 Hr.)
for 48 hours after cool-down is completed, then it may be taken
Cold Start off of turning gear.
50% 4% 80%
(Down >40 Hr.)
Figure F-1 also provides guidelines for hot restarts. When an
Hours/Start 4 16 400
immediate restart is required, it is recommended that the rotor
Hours/Year 600 4800 8200
be placed on turning gear for one hour following a trip from load,
Starts/Year 150 300 21
trip from full speed no load, or normal shutdown. This will allow
Percent Trips 3% 1% 20% transient thermal stresses to subside before superimposing a
Trips/Year 5 3 4 startup transient. If the machine must be restarted in less than
Typical Maintenance one hour, a start factor of 2 will apply.
1.7 1.0 NA
Factor (Starts-Based)
Longer periods of turning gear operation may be necessary prior to
• Operational Profile is Application Specific a cold start or hot restart if bow is detected. Vibration data taken
• Inspection Interval is Application Specific while at crank speed can be used to confirm that rotor bow is at
Figure 23. 7F gas turbine typical operational profile acceptable levels and the start sequence can be initiated. Users
should reference the O&M Manual and appropriate TILs for specific
Baseline Unit instructions and information for their units.
Cyclic Duty
6 Starts/Week
Combustion Parts
A typical combustion system contains transition pieces,
16 Hours/Start
combustion liners, flow sleeves, head-end assemblies containing
4 Outage/Year Maintenance
fuel nozzles and cartridges, end caps and end covers, and assorted
50 Weeks/Year other hardware including cross-fire tubes, spark plugs and flame
4800 Hours/Year detectors. In addition, there can be various fuel and air delivery
300 Starts/Year components such as purge or check valves and flex hoses. GE
0 Trips/Year provides several types of combustion systems including standard

1 Maintenance Factor combustors, Multi-Nozzle Quiet Combustors (MNQC), Integrated

Gasification Combined Cycle (IGCC) combustors, and Dry Low NOx
12 Cold Starts/Year (down >40 Hr.) 4%
(DLN) combustors. Each of these combustion systems has unique
39 Warm 2 Starts/Year (Down 20-40 Hr.) 13%
operating characteristics and modes of operation with differing
246 Warm 1 Starts/Year (Down 4-20 Hr.) 82%
responses to operational variables affecting maintenance and
3 Hot 2 Starts/Year (Down 1-4 Hr.) 1% refurbishment requirements.
Baseline Unit Achieves Maintenance Factor = 1
DLN combustion systems use various combustion modes to reach
Figure 24. Baseline for starts-based maintenance factor definition
base load operation. The system transfers from one combustion
mode to the next when the calculated value of firing temperature

GE Power & Water | GER-3620M (05/14) 15

increases to the required value, or transfer temperature, for the tune the combustion system to levels of acoustic dynamics low
next mode. enough to ensure that the maintenance practices described here
are not compromised. In addition, GE encourages monitoring of
• Continuous mode operation is defined as operation in a
combustion dynamics during turbine operation throughout the
combustion mode for longer than what is required during normal
full range of ambient temperatures and loads.
startup/shutdown.
Combustion disassembly is performed, during scheduled
• Extended mode operation is defined as operation in a
combustion inspections (CI). Inspection interval guidelines are
combustion mode at a firing temperature greater than the
included in Figure 39. It is expected, and recommended, that
transfer temperature to the next combustion mode.
intervals be modified based on specific experience. Replacement
The DLN combustion mode recommended for continuous mode intervals are usually defined by a recommended number of
operation is the premixed combustion mode (PM), as it achieves combustion (or repair) intervals and are usually combustion
lowest possible emissions and maximum possible part life. component specific. In general, the replacement interval as a
Continuous and extended mode operation in non-PM combustion function of the number of combustion inspection intervals is
modes is not recommended due to its effect on combustion reduced if the combustion inspection interval is extended. For
hardware life as shown in Figure 25. The use of non-PM combustion example, a component having an 8,000-hour CI interval, and a
modes has the following effects on maintenance: six CI replacement interval, would have a replacement interval of
• DLN-1/DLN-1+ extended lean-lean operation results in a four CI intervals if the inspection interval were increased to 12,000
maintenance factor of 10 (excluding Frame 5 units where MF=2). hours (to maintain a 48,000-hour replacement interval).

• DLN 2.0/DLN 2+ extended piloted premixed operation results in a For combustion parts, the baseline operating conditions that result
maintenance factor of 10. in a maintenance factor of one are fired startup and shutdown to
base load on natural gas fuel without steam or water injection.
• Continuous mode operation in lean-lean (L-L), sub-piloted
Factors that increase the hours-based maintenance factor include
premixed (sPPM), or piloted premixed (PPM) modes is not
peak load operation, distillate or heavy fuels, and steam or water
recommended as it will accelerate combustion hardware
injection. Factors that increase starts-based maintenance factor
degradation.
include peak load start/stop cycles, distillate or heavy fuels, steam
• In addition, cyclic operation between piloted premixed and or water injection, trips, and peaking-fast starts.
premixed modes leads to thermal loads on the combustion liner
and transition piece similar to the loads encountered during the Casing Parts
startup/shutdown cycle. Most GE gas turbines have inlet, compressor, compressor
Severity discharge, and turbine cases in addition to exhaust frames. Inner
~85% TNH FSNL Full Load High
barrels are typically attached to the compressor discharge case.
Combustor Combustion mode effect on hardware life
These cases provide the primary support for the bearings, rotor,
Premixed
DLN 1/1+ Primary L-L and gas path hardware.
Extended L-L
Premixed
DLN 2.0/2+ Diffusion L-L/sPPM PPM The exterior of all casings should be visually inspected for cracking,
Extended PPM Low
loose hardware, and casing slippage at each combustion, hot
Figure 25. DLN combustion mode effect on combustion hardware life
gas path, and major outage. The interior of all casings should
Another factor that can affect combustion system maintenance be inspected whenever possible. The level of the outage
is acoustic dynamics. Acoustic dynamics are pressure oscillations determines which casing interiors are accessible for visual
generated by the combustion system, which, if high enough inspection. Borescope inspections are recommended for the
in magnitude, can lead to significant wear and cracking of inlet cases, compressor cases, and compressor discharge cases
combustion or hot gas path components. GE practice is to

16
during gas path borescope inspections. All interior case surfaces normally axial diffusers, while aft diffusers can be either axial or
should be visually inspected during a major outage. radial. Axial diffusers are used in the F-class gas turbines, while
radial diffusers are used in B/E-class gas turbines.
Key inspection areas for casings are listed below.
Exhaust diffusers are subject to high gas path temperatures and
• Bolt holes
vibration due to normal gas turbine operation. Because of the
• Shroud pin and borescope holes in the turbine shell (case) extreme operating environment and cyclic operating nature of
• Compressor stator hooks gas turbines, exhaust diffusers may develop cracks in the sheet
metal surfaces and weld joints used for diffuser construction.
• Turbine shell shroud hooks
Additionally, erosion may occur due to extended operation at high
• Compressor discharge case struts temperatures. Exhaust diffusers should be inspected for cracking
• Inner barrel and inner barrel bolts and erosion at every combustion, hot gas path and major outage.

• Inlet case bearing surfaces and hooks In addition, flex seals, L-seals, and horizontal joint gaskets should
be visually/borescope inspected for signs of wear or damage
• Inlet case and exhaust frame gibs and trunions
at every combustion, hot gas path, and major outage. GE
• Extraction manifolds (for foreign objects) recommends that seals with signs of wear or damage be replaced.

Exhaust Diffuser Parts To summarize, key areas that should be inspected are listed below.

GE exhaust diffusers come in either axial or radial configurations Any damage should be reported to GE for recommended repairs.

as shown in Figures 26 and 27 below. Both types of diffusers are • Forward diffuser carrier flange (6F)
composed of a forward and aft section. Forward diffusers are
• Diffuser strut airfoil leading and trailing edges

• Turning vanes in radial diffusers (B/E-class)

• Insulation packs on interior or exterior surfaces

• Clamp ring attachment points to exhaust frame

(major outage only)

• Flex seals and L-seals

• Horizontal joint gaskets

Off-Frequency Operation
GE heavy-duty single shaft gas turbines are engineered to operate
Figure 26. F-class axial diffuser
at 100% speed with the capability to operate over a 95% to
105% speed range. Operation at other than rated speed has the
potential to affect maintenance requirements. Depending on the
industry code requirements, the specifics of the turbine design,
and the turbine control philosophy employed, operating conditions
can result that will accelerate life consumption of gas turbine
components, particularly rotating flowpath hardware. Where this
is true, the maintenance factor associated with this operation must
be understood. These off-frequency events must be analyzed and
recorded in order to include them in the maintenance plan for the
Figure 27. E-class radial diffuser gas turbine.

GE Power & Water | GER-3620M (05/14) 17

Some turbines are required to meet operational requirements Over Speed Operation
that are aimed at maintaining grid stability under sudden load Constant Tfire
10.0
or capacity changes. Most codes require turbines to remain on

Maintenance Factor (MF)

line in the event of a frequency disturbance. For under-frequency
operation, the turbine output may decrease with a speed decrease,
and the net effect on the turbine is minimal.

In some cases of under-frequency operation, turbine output must MF = 2

be increased in order to meet the specification-defined output

requirement. If the normal output fall-off with speed results in loads
less than the defined minimum, the turbine must compensate. 1.0
100 101 102 103 104 105
Turbine overfiring is the most obvious compensation option, but
% Speed
other means, such as water-wash, inlet fogging, or evaporative Figure 28. Maintenance factor for overspeed operation ~constant TF
cooling also provide potential means for compensation. A
maintenance factor may need to be applied for some of these Compressor Condition and Performance
methods. In addition, off-frequency operation, including rapid grid Maintenance and operating costs are also influenced by the quality
transients, may expose the blading to excitations that could result in of the air that the turbine consumes. In addition to the negative
blade resonant response and reduced fatigue life. effects of airborne contaminants on hot gas path components,

It is important to understand that operation at over-frequency contaminants such as dust, salt, and oil can cause compressor

conditions will not trade one-for-one for periods at under- blade erosion, corrosion, and fouling.

frequency conditions. As was discussed in the firing temperature Fouling can be caused by submicron dirt particles entering the
section above, operation at peak firing conditions has a nonlinear, compressor as well as from ingestion of oil vapor, smoke, sea salt,
logarithmic relationship with maintenance factor. and industrial vapors. Corrosion of compressor blading causes

Over-frequency or high speed operation can also introduce pitting of the blade surface, which, in addition to increasing the

conditions that affect turbine maintenance and part replacement surface roughness, also serves as potential sites for fatigue crack

intervals. If speed is increased above the nominal rated speed, initiation. These surface roughness and blade contour changes

the rotating components see an increase in mechanical stress will decrease compressor airflow and efficiency, which in turn

proportional to the square of the speed increase. If firing reduces the gas turbine output and overall thermal efficiency.

temperature is held constant at the overspeed condition, the Generally, axial flow compressor deterioration is the major cause

life consumption rate of hot gas path rotating components will of loss in gas turbine output and efficiency. Recoverable losses,

increase as illustrated in Figure 28 where one hour of operation at attributable to compressor blade fouling, typically account for

105% speed is equivalent to two hours at rated speed. 70-85% percent of the performance losses seen. As Figure 29
illustrates, compressor fouling to the extent that airflow is
If overspeed operation represents a small fraction of a turbine’s
reduced by 5%, will reduce output by up to 8% and increase heat
operating profile, this effect on parts life can sometimes be
rate by up to 3%. Fortunately, much can be done through proper
ignored. However, if significant operation at overspeed is expected
operation and maintenance procedures both to minimize fouling
and rated firing temperature is maintained, the accumulated hours
type losses and to limit the deposit of corrosive elements. On-line
must be recorded and included in the calculation of the turbine’s
compressor wash systems are available to maintain compressor
overall maintenance factor and the maintenance schedule
efficiency by washing the compressor while at load, before
adjusted to reflect the overspeed operation.
significant fouling has occurred. Off-line compressor wash
systems are used to clean heavily fouled compressors. Other
procedures include maintaining the inlet filtration system, inlet

18
 4% Moisture Intake
Heat Rate Increase

One of the ways some users increase turbine output is through

2%
the use of inlet foggers. Foggers inject a large amount of moisture
in the inlet ducting, exposing the forward stages of the compressor
0%
to potential water carry-over. Operation of a compressor in such

5% Airflow Loss
-2% an environment may lead to long-term degradation of the
Output Loss

compressor due to corrosion, erosion, fouling, and material

-4% property degradation. Experience has shown that depending on
the quality of water used, the inlet silencer and ducting material,
-6% and the condition of the inlet silencer, fouling of the compressor
can be severe with inlet foggers. Similarly, carryover from
-8%
0% 1% 2% 3% 4% 5% evaporative coolers and water washing more than recommended
Pressure Ratio Decrease can degrade the compressor. Figure 30 shows the long-term
Figure 29. Deterioration of gas turbine performance due to compressor material property degradation resulting from operating the
blade fouling
compressor in a wet environment. The water quality standard
evaporative coolers, and other inlet systems as well as periodic that should be adhered to is found in GEK-101944, “Requirements
inspection and prompt repair of compressor blading. Refer to for Water/Steam Purity in Gas Turbines.”
system-specific maintenance manuals.
For turbines with AISI 403 stainless steel compressor blades, the
There are also non-recoverable losses. In the compressor, these are presence of water carry-over will reduce blade fatigue strength
typically caused by nondeposit-related blade surface roughness, by as much as 30% and increase the crack propagation rate in
erosion, and blade tip rubs. In the turbine, nozzle throat area a blade if a flaw is present. The carry-over also subjects the
changes, bucket tip clearance increases and leakages are potential blades to corrosion. Such corrosion may be accelerated by a
causes. Some degree of unrecoverable performance degradation saline environment (see GER-3419). Further reductions in fatigue
should be expected, even on a well-maintained gas turbine. The strength will result if the environment is acidic and if pitting is
owner, by regularly monitoring and recording unit performance present on the blade. Pitting is corrosion-induced, and blades
parameters, has a very valuable tool for diagnosing possible with pitting can see material strength reduced to 40% of its
compressor deterioration. original value. This condition is exacerbated by downtime in
humid environments, which promotes wet corrosion.
Lube Oil Cleanliness
Contaminated or deteriorated lube oil can cause wear and damage Effect of Corrosive Environment
• Reduces Vane Material Endurance Strength
to bearing liners. This can lead to extended outages and costly
• Pitting Provides Localized Stress Risers
repairs. Routine sampling of the turbine lube oil for proper viscosity,
Fatigue Sensitivity to Environment
chemical composition, and contamination is an essential part of a ISO
1.0
200°F
complete maintenance plan. 0.9
Alternating Stress Ratio

0.8 Wet Steam

Lube oil should be sampled and tested per GEK-32568, “Lubricating ISO
0.7
Acid H2O 180°F
Oil Recommendations for Gas Turbines with Bearing Ambients 0.6
0.5
Above 500°F (260°C).” Additionally, lube oil should be checked Pitted in Air
0.4
periodically for particulate and water contamination as outlined 0.3
in GEK-110483, “Cleanliness Requirements for Power Plant 0.2

Installation, Commissioning and Maintenance.” At a minimum, 0.1

0.0
the lube oil should be sampled on a quarterly basis; however, Estimated Fatigue Strength (107 Cycles) for AISI 403 Blades
monthly sampling is recommended. Figure 30. Long-term material property degradation in a wet environment

GE Power & Water | GER-3620M (05/14) 19

Uncoated GTD-450™ material is relatively resistant to corrosion The disassembly inspection requires opening the turbine for
while uncoated AISI 403 is more susceptible. Relative susceptibility inspection of internal components. Disassembly inspections
of various compressor blade materials and coatings is shown in progress from the combustion inspection to the hot gas path
Figure 31. As noted in GER-3569, aluminum-based (Al) coatings are inspection to the major inspection as shown in Figure 32.
susceptible to erosion damage leading to unprotected sections Details of each of these inspections are described below.
of the blade. Because of this, the GECC-1™ coating was created
to combine the effects of an Al coating to prevent corrosion and Standby Inspections
a ceramic topcoat to prevent erosion. Water droplets will cause Standby inspections are performed on all gas turbines but

leading edge erosion on the first few stages of the compressor. This pertain particularly to gas turbines used in peaking and

erosion, if sufficiently developed, may lead to an increased risk of intermittent-duty service where starting reliability is of primary

blade failure. concern. This inspection includes routinely servicing the battery
system, changing filters, checking oil and water levels, cleaning

GTD-450 Bare relays, and checking device calibrations. Servicing can be

performed in off-peak periods without interrupting the
Al Slurry Coatings
availability of the turbine. A periodic startup test run is an
NiCd+ Topcoats
essential part of the standby inspection.
AISI 403 Ceramic
The O&M Manual, as well as the Service Manual Instruction
NiCd Books, contains information and drawings necessary to

Bare perform these periodic checks. Among the most useful

drawings in the Service Manual Instruction Books for standby
0 2 4 6 8 10
Worst Best maintenance are the control specifications, piping schematics,
Relative Corrosion Resistance
and electrical elementaries. These drawings provide the
Figure 31. Susceptibility of compressor blade materials and coatings calibrations, operating limits, operating characteristics, and
sequencing of all control devices. This information should be

Utilization of inlet fogging or evaporative cooling may also used regularly by operating and maintenance personnel.

introduce water carry-over or water ingestion into the compressor, Careful adherence to minor standby inspection maintenance

resulting in blade erosion. Although the design intent of evaporative can have a significant effect on reducing overall maintenance

coolers and inlet foggers is to fully vaporize all cooling water costs and maintaining high turbine reliability. It is essential that

prior to its ingestion into the compressor, evidence suggests that, a good record be kept of all inspections and maintenance work

on systems that are not properly commissioned, maintained, or in order to ensure a sound maintenance program.

operated, the water may not be fully vaporized. This can be seen
Running Inspections
by streaking discoloration on the inlet duct or bell mouth. If this is
Running inspections consist of the general and continued
the case, additional inspections and maintenance are required, as
observations made while a unit is operating. This starts by
presented in applicable TILs and GEKs.
establishing baseline operating data during startup of a new

Maintenance Inspections unit and after any major disassembly work. This baseline then
serves as a reference from which subsequent unit deterioration
Maintenance inspection types may be broadly classified as
can be measured.
standby, running, and disassembly inspections. The standby
inspection is performed during off-peak periods when the unit is Data should be taken to establish normal equipment startup

not operating and includes routine servicing of accessory systems parameters as well as key steady state operating parameters.

and device calibration. The running inspection is performed by Steady state is defined as conditions at which no more than

observing key operating parameters while the turbine is running. a 5°F/3°C change in wheelspace temperature occurs over a

20
 Major Inspection

Hot Gas Path

Disassembly Inspections Inspection
• Combustion
• Hot Gas Path
Combustion
• Major Inspection

Figure 32. 7E.03 heavy-duty gas turbine – disassembly inspections

15-minute time period. Data must be taken at regular intervals • Speed

and should be recorded to permit an evaluation of the turbine
• Load
performance and maintenance requirements as a function of
• Fired Starts
operating time. This operating inspection data, summarized in
Figure 33, includes: load versus exhaust temperature, vibration • Fired Hours

level, fuel flow and pressure, bearing metal temperature, lube • Temperatures
oil pressure, exhaust gas temperatures, exhaust temperature – Inlet Ambient – Lube Oil Tank
– Compressor Discharge – Bearing Metal
spread variation, startup time, and coast-down time. This list
– Turbine Exhaust – Bearing Drains
is only a minimum and other parameters should be used as
– Turbine Wheelspace – Exhaust Spread
necessary. A graph of these parameters will help provide a basis – Lube Oil Header
for judging the conditions of the system. Deviations from the
• Pressures
norm help pinpoint impending issues, changes in calibration, or
– Compressor Discharge – Cooling Water
damaged components. – Lube Pump(s) – Fuel
– Bearing Header – Filters (Fuel, Lube, Inlet Air)
A sudden abnormal change in running conditions or a severe trip
– Barometric
event could indicate damage to internal components. Conditions
that may indicate turbine damage include high vibration, high • Vibration
exhaust temperature spreads, compressor surge, abnormal • Generator
changes in health monitoring systems, and abnormal changes – Output Voltage – Field Voltage
in other monitoring systems. It is recommended to conduct a – Phase Current – Field Current
– VARS – Stator Temp.
borescope inspection after such events whenever component
– Load – Vibration
damage is suspected.
• Startup Time
• Coast-Down Time

Figure 33. Operating inspection data parameters

GE Power & Water | GER-3620M (05/14) 21

Load vs. Exhaust Temperature Close observation and monitoring of these operating parameters
The general relationship between load and exhaust temperature will serve as the basis for effectively planning maintenance
should be observed and compared to previous data. Ambient work and material requirements needed for subsequent
temperature and barometric pressure will have some effect shutdown periods.
upon the exhaust temperature. High exhaust temperature can
be an indicator of deterioration of internal parts, excessive leaks
Rapid Cool-Down
Prior to an inspection, a common practice is to force cool the unit
or a fouled air compressor. For mechanical drive applications,
to speed the cool-down process and shorten outage time. Force
it may also be an indication of increased power required by
cooling involves turning the unit at crank speed for an extended
the driven equipment.
period of time to continue flowing ambient air through the
Vibration Level machine. This is permitted, although a natural cool-down cycle
The vibration signature of the unit should be observed and on turning gear or ratchet is preferred for normal shutdowns
recorded. Minor changes will occur with changes in operating when no outage is pending.
conditions. However, large changes or a continuously increasing
Forced cooling should be limited since it imposes additional
trend give indications of the need to apply corrective action.
thermal stresses on the unit that may result in a reduction of
parts life.
Fuel Flow and Pressure
The fuel system should be observed for the general fuel flow Opening the compartment doors during any cool-down
versus load relationship. Fuel pressures through the system operation is prohibited unless an emergency situation requires
should be observed. Changes in fuel pressure can indicate that immediate compartment inspection. Cool-down times should not
the fuel nozzle passages are plugged or that fuel-metering be accelerated by opening the compartment doors or lagging
elements are damaged or out of calibration. panels, since uneven cooling of the outer casings may result in
excessive case distortion and heavy blade rubs.
Exhaust Temperature and Spread Variation
The most important control function to be monitored is the Combustion Inspection
exhaust temperature fuel override system and the back-up over The combustion inspection is a relatively short disassembly
temperature trip system. Routine verification of the operation inspection of fuel nozzles, liners, transition pieces, crossfire
and calibration of these functions will minimize wear on the tubes and retainers, spark plug assemblies, flame detectors,
hot gas path parts. and combustor flow sleeves. This inspection concentrates on the
combustion liners, transition pieces, fuel nozzles, and end caps,
Startup Time which are recognized as being the first to require replacement
Startup time is a reference against which subsequent operating and repair in a good maintenance program. Proper inspection,
parameters can be compared and evaluated. A curve of the maintenance, and repair (Figure 34) of these items will contribute
starting parameters of speed, fuel signal, exhaust temperature, to a longer life of the downstream parts, such as turbine nozzles
and critical sequence bench marks versus time will provide a good and buckets.
indication of the condition of the control system. Deviations from
Figure 32 illustrates the section of a 7E.03 unit that is disassembled
normal conditions may indicate impending issues, changes in
for a combustion inspection. The combustion liners, transition
calibration, or damaged components.
pieces, and fuel nozzle assemblies should be removed and
Coast-Down Time replaced with new or repaired components to minimize downtime.
Coast-down time is an indicator of bearing alignment and bearing The removed liners, transition pieces, and fuel nozzles can then be
condition. The time period from when the fuel is shut off during a cleaned and repaired after the unit is returned to operation and
normal shutdown until the rotor comes to turning gear speed can be available for the next combustion inspection interval. Typical
be compared and evaluated. combustion inspection requirements are:

22
• Inspect combustion chamber components. • Inspect all fluid, air, and gas passages in nozzle assembly for
plugging, erosion, burning, etc.
• Inspect each crossfire tube, retainer and combustion liner.
• Inspect spark plug assembly for freedom from binding; check
• Inspect combustion liner for TBC spalling, wear, and cracks.
condition of electrodes and insulators.
• Inspect combustion system and discharge casing for debris and
• Replace all consumables and normal wear-and-tear items such
foreign objects.
as seals, lockplates, nuts, bolts, gaskets, etc.
• Inspect flow sleeve welds for cracking.
• Perform visual inspection of first-stage turbine nozzle partitions
• Inspect transition piece for wear and cracks. and borescope inspect (Figure 3) turbine buckets to mark the
• Inspect fuel nozzles for plugging at tips, erosion of tip holes, and progress of wear and deterioration of these parts. This inspection
safety lock of tips. will help establish the schedule for the hot gas path inspection.

• Inspect impingement sleeves for cracks (where applicable). • Perform borescope inspection of compressor.

Combustion Inspection
Key Hardware Inspect For Potential Action
Combustion liners Foreign object damage (FOD) Repair/refurbish/replace
Combustion end covers Abnormal wear • Transition Pieces • Fuel nozzles
Fuel nozzles Cracking – Strip and recoat – Weld repair
End caps Liner cooling hole plugging – Weld repair – Flow test

Transition pieces TBC coating condition – Creep repair – Leak test

Cross fire tubes Oxidation/corrosion/erosion • Liners

Flow sleeves Hot spots/burning – Strip and recoat

– Weld repair
Purge valves Missing hardware
– Hula seal
Check valves Clearance limits
replacement
Spark plugs
– Repair out-of-
Flame detectors roundness
Flex hoses
IGVs and bushings
Compressor and turbine (borescope)
Exhaust diffuser Cracks Weld repair
Exhaust diffuser Insulation Loose/missing parts Replace/tighten parts
Forward diffuser flex seal Wear/cracked parts Replace seals
Compressor discharge case Cracks Repair or monitor
Cases – exterior Cracks Repair or monitor

Criteria Inspection Methods Availability of On-Site Spares

• O&M Manual • TILs • Visual • Liquid Penetrant is Key to Minimizing Downtime
• GE Field Engineer • Borescope

Figure 34. Combustion inspection – key elements

GE Power & Water | GER-3620M (05/14) 23

• Visually inspect the compressor inlet, checking the condition • Verify proper operation of purge and check valves. Confirm
of the inlet guide vanes (IGVs), IGV bushings, and first stage proper setting and calibration of the combustion controls.
rotating blades.
• Inspect turbine inlet systems including filters, evaporative
• Check the condition of IGV actuators and rack-and-pinion gearing. coolers, silencers, etc. for corrosion, cracks, and loose parts.

• Verify the calibration of the IGVs. After the combustion inspection is complete and the unit is
returned to service, the removed combustion hardware can
• Visually inspect compressor discharge case struts for signs
be inspected by a qualified GE field service representative and,
of cracking.
if necessary, sent to a qualified GE Service Center for repairs.
• Visually inspect compressor discharge case inner barrel It is recommended that repairs and fuel nozzle flow testing be
if accessible. performed at qualified GE service centers.
• Visually inspect the last-stage buckets and shrouds. See the O&M Manual for additional recommendations and unit
• Visually inspect the exhaust diffuser for any cracks in flow specific guidance.
path surfaces. Inspect insulated surfaces for loose or missing
insulation and/or attachment hardware in internal and external
Hot Gas Path Inspection
The purpose of a hot gas path inspection is to examine those parts
locations. In B/E-class machines, inspect the insulation on the
exposed to high temperatures from the hot gases discharged from
radial diffuser and inside the exhaust plenum as well.
the combustion process. The hot gas path inspection outlined
• Inspect exhaust frame flex seals, L-seals, and horizontal joint in Figure 35 includes the full scope of the combustion inspection
gaskets for any signs of wear or damage. and, in addition, a detailed inspection of the turbine nozzles,

Hot Gas Path Inspection

Combustion Inspection Scope—Plus:
Key Hardware Inspect For Potential Action
Nozzles (1, 2, 3) Foreign object damage Repair/refurbish/replace
Buckets (1, 2, 3) Oxidation/corrosion/erosion • Nozzles • Buckets
Stator shrouds Cracking – Weld repair – Strip & recoat
Compressor blading (borescope) Cooling hole plugging – Reposition – Weld repair

Remaining coating life – Recoat – Blend

• Stator shrouds
Nozzle deflection/distortion
– Weld repair
Abnormal deflection/distortion
– Blend
Abnormal wear
– Recoat
Missing hardware
Clearance limits
Evidence of creep
Turbine shell Cracks Repair or monitor

Criteria Inspection Methods Availability of On-Site Spares

• O&M Manual • TILs • Visual • Liquid Penetrant is Key to Minimizing Downtime
• GE Field Engineer • Borescope

Figure 35. Hot gas path inspection – key elements

24
stator shrouds, and turbine buckets. To perform this inspection, be removed, follow bucket removal and condition recording
the top half of the turbine shell must be removed. Prior to shell instructions. Buckets with protective coating should be
removal, proper machine centerline support using mechanical evaluated for remaining coating life.
jacks is necessary to assure proper alignment of rotor to stator,
• Inspect and record condition of first-, second-, and
obtain accurate half-shell clearances, and prevent twisting of
third-stage nozzles.
the stator casings. Reference the O&M Manual for unit-specific
jacking procedures. • Inspect seals and hook fits of turbine nozzles and diaphragms
for rubs, erosion, fretting, or thermal deterioration.
Special inspection procedures apply to specific components
in order to ensure that parts meet their intended life. These • Inspect and record condition of later-stage nozzle

inspections may include, but are not limited to, dimensional diaphragm packings.

inspections, Fluorescent Penetrant Inspection (FPI), Eddy Current • Check discourager seals for rubs, and deterioration
Inspection (ECI), and other forms of non-destructive testing (NDT). of clearance.
The type of inspection required for specific hardware is determined
• Record the bucket tip clearances.
on a part number and operational history basis, and can be
obtained from a GE service representative. • Inspect bucket shank seals for clearance, rubs, and deterioration.

Similarly, repair action is taken on the basis of part number, unit • Perform inspections on cutter teeth of tip-shrouded buckets.

operational history, and part condition. Repairs including (but not Consider refurbishment of buckets with worn cutter teeth,

limited to) strip, chemical clean, HIP (Hot Isostatic Processing), particularly if concurrently refurbishing the honeycomb of the

heat treat, and recoat may also be necessary to ensure full parts corresponding stationary shrouds. Consult your GE service

life. Weld repair will be recommended when necessary, typically representative to confirm that the bucket under consideration

as determined by visual inspection and NDT. Failure to perform is repairable.

the required repairs may lead to retirement of the part before • Check the turbine stationary shrouds for clearance, cracking,
its life potential is fulfilled. In contrast, unnecessary repairs are erosion, oxidation, rubbing, and build-up of debris.
an unneeded expenditure of time and resources. To verify the
• Inspect turbine rotor for cracks, object damage, or rubs.
types of inspection and repair required, contact your GE service
representative prior to an outage. • Check and replace any faulty wheelspace thermocouples.

For inspection of the hot gas path (Figure 32), all combustion • Perform borescope inspection of the compressor.
transition pieces and the first-stage turbine nozzle assemblies must • Visually inspect the turbine shell shroud hooks for signs
be removed. Removal of the second- and third-stage turbine nozzle of cracking.
segment assemblies is optional, depending upon the results of
The first-stage turbine nozzle assembly is exposed to the direct hot
visual observations, clearance measurements, and other required
gas discharge from the combustion process and is subjected to the
inspections. The buckets can usually be inspected in place. FPI of
highest gas temperatures in the turbine section. Such conditions
the bucket vane sections may be required to detect any cracks.
frequently cause nozzle cracking and oxidation, and in fact, this
In addition, a complete set of internal turbine radial and axial
is expected. The second- and third-stage nozzles are exposed to
clearances (opening and closing) must be taken during any hot
high gas bending loads, which in combination with the operating
gas path inspection. Re-assembly must meet clearance diagram
temperatures can lead to downstream deflection and closure
requirements to prevent rubs and to maintain unit performance.
of critical axial clearances. To a degree, nozzle distress can be
In addition to combustion inspection requirements, typical hot gas
tolerated, and criteria have been established for determining when
path inspection requirements are:
repair is required. More common criteria are described in the O&M
• Inspect and record condition of first-, second-, and third-stage Manuals. However, as a general rule, first-stage nozzles will require
buckets. If it is determined that the turbine buckets should

GE Power & Water | GER-3620M (05/14) 25

repair at the hot gas path inspection. The second- and third-stage it should be done before the coating is breached to expose base
nozzles may require refurbishment to re-establish the proper axial metal. Normally, for 7E.03 turbines, this means that recoating
clearances. Normally, turbine nozzles can be repaired several will be required at the hot gas path inspection. If recoating is not
times, and it is generally repair cost versus replacement cost that performed at the hot gas path inspection, the life of the buckets
dictates the replacement decision. would generally be one additional hot gas path inspection interval,
at which point the buckets would be replaced. For F-class gas
Coatings play a critical role in protecting the buckets operating
turbines, recoating of the first stage buckets is recommended at
at high metal temperatures. They ensure that the full capability
each hot gas path inspection. Visual and borescope examination
of the high strength superalloy is maintained and that the bucket
of the hot gas path parts during the combustion inspections as
rupture life meets design expectations. This is particularly true
well as nozzle-deflection measurements will allow the operator
of cooled bucket designs that operate above 1985°F (1085°C)
to monitor distress patterns and progression. This makes part-
firing temperature. Significant exposure of the base metal to
life predictions more accurate and allows adequate time to plan
the environment will accelerate the creep rate and can lead to
for replacement or refurbishment at the time of the hot gas path
premature replacement through a combination of increased
inspection. It is important to recognize that to avoid extending the
temperature and stress and a reduction in material strength,
hot gas path inspection, the necessary spare parts should be on
as described in Figure 36. This degradation process is driven by
site prior to taking the unit out of service.
oxidation of the unprotected base alloy. On early generation
uncooled designs, surface degradation due to corrosion or See the O&M Manual for additional recommendations and unit
oxidation was considered to be a performance issue and not a specific guidance.
factor in bucket life. This is no longer the case at the higher firing
temperatures of current generation designs. Major Inspection
The purpose of the major inspection is to examine all of the internal
Given the importance of coatings, it must be recognized that even
rotating and stationary components from the inlet of the machine
the best coatings available will have a finite life, and the condition
through the exhaust. A major inspection should be scheduled in
of the coating will play a major role in determining bucket life.
accordance with the recommendations in the owner’s O&M Manual
Refurbishment through stripping and recoating is an option for
or as modified by the results of previous borescope and hot gas
achieving bucket’s expected/design life, but if recoating is selected,
path inspections. The work scope shown in Figure 37 involves

Oxidation & Bucket Life

Base Metal Oxidation

Cooling Hole
Surface Oxidation

Depleted Coating
Increases Stress
Airfoil Surface • Reduced Load Carrying Cross Section
TE Cooling Hole Oxidation
Increases Metal Temperature
• Surface Roughness Effects

Decreases Alloy Creep Strength

• Environmental Effects

Pressure Side Surface

Reduces Bucket Creep Life

Figure 36. Stage 1 bucket oxidation and bucket life

26
inspection of all of the major flange-to-flange components of • Check all radial and axial clearances against their original values
the gas turbine, which are subject to deterioration during normal (opening and closing).
turbine operation. This inspection includes previous elements of the
• Inspect all casings, shells, and frames/diffusers for cracks
combustion and hot gas path inspections, and requires laying open
and erosion.
the complete flange-to-flange gas turbine to the horizontal joints,
as shown in Figure 32. • Inspect compressor inlet and compressor flow-path for fouling,
erosion, corrosion, and leakage.
Removal of all of the upper casings allows access to the
compressor rotor and stationary compressor blading, as well as • Check rotor and stator compressor blades for tip clearance,

to the bearing assemblies. Prior to removing casings, shells, and rubs, object damage, corrosion pitting, and cracking.

frames, the unit must be properly supported. Proper centerline • Remove turbine buckets and perform a nondestructive check
support using mechanical jacks and jacking sequence procedures of buckets and wheel dovetails. Wheel dovetail fillets, pressure
are necessary to assure proper alignment of rotor to stator, obtain faces, edges, and intersecting features must be closely examined
accurate half shell clearances, and to prevent twisting of the for conditions of wear, galling, cracking, or fretting.
casings while on the half shell. Reference the O&M Manual for
• Inspect unit rotor for cracks, object damage, or rubs.
unit-specific jacking procedures. In addition to combustion and
hot gas path inspection requirements, typical major inspection • Inspect bearing liners and seals for clearance and wear.
requirements are:

Major Inspection
Hot Gas Path Inspection Scope—Plus:
Key Hardware Inspect For Potential Action
Compressor blading Foreign object damage Repair/refurbishment/replace
Unit rotor Oxidation/corrosion/erosion • Bearings/seals
Journals and seal surfaces Cracking – Clean
Bearing seals Leaks – Assess oil condition
Exhaust system Abnormal wear – Re-babbitt
Missing hardware • Compressor blades
Clearance limits – Clean
Coating wear – Blend
Fretting • Exhaust system
– Weld repair
– Replace flex seals/L-seals
Compressor and compressor
Wear Repair
discharge case hooks
All cases – exterior and interior Cracks Repair or monitor
Cases – Exterior Slippage Casing alignment

Criteria Inspection Methods

• O&M Manual • TILs • Visual • Liquid Penetrant
• GE Field Engineer • Borescope • Ultrasonics

Figure 37. Gas turbine major inspection – key elements

GE Power & Water | GER-3620M (05/14) 27

• Visually inspect compressor and compressor discharge case The actual repair and replacement intervals for any particular
hooks for signs of wear. gas turbine should be based on the user’s operating procedures,
experience, maintenance practices, and repair practices. The
• Visually inspect compressor discharge case inner barrel.
maintenance factors previously described can have a major effect
• Inspect exhaust frame flex seals, L-seals, and horizontal joint on both the component repair interval and service life. For this
gaskets for any signs of wear or damage. Inspect steam gland reason, the intervals given in Appendix D should only be used
seals for wear and oxidation. as guidelines and not certainties for long range parts planning.
• Check torque values for steam gland bolts and re-torque Owners may want to include contingencies in their parts planning.
to full values. The estimated repair and replacement interval values reflect
• Check alignment – gas turbine to generator/gas turbine to current production hardware (the typical case) with design
accessory gear. improvements such as advanced coatings and cooling technology.
With earlier production hardware, some of these lives may not be
• Inspect casings for signs of casing flange slippage.
achievable. Operating factors and experience gained during the
Comprehensive inspection and maintenance guidelines have been course of recommended inspection and maintenance procedures
developed by GE and are provided in the O&M Manual to assist will be a more accurate predictor of the actual intervals.
users in performing each of the inspections previously described.
The estimated repair and replacement intervals are based on

Parts Planning the recommended inspection intervals shown in Figure 39. For
certain models, technology upgrades are available that extend the
Prior to a scheduled disassembly inspection, adequate spares
maintenance inspection intervals. The application of inspection (or
should be on-site. Lack of adequate on-site spares can have
repair) intervals other than those shown in Figure 39 can result in
a major effect on plant availability. For example, a planned
different replacement intervals than those shown in Appendix D.
outage such as a combustion inspection, which should only
See your GE service representative for details on a specific system.
take two to five days, could take weeks if adequate spares are
not on-site. GE will provide recommendations regarding the It should be recognized that, in some cases, the service life of a
types and quantities of spare parts needed; however, it is up component is reached when it is no longer economical to repair
to the owner to purchase these spare parts on a planned basis any deterioration as opposed to replacing at a fixed interval. This
allowing adequate lead times. is illustrated in Figure 38 for a first stage nozzle, where repairs
continue until either the nozzle cannot be restored to minimum
Early identification of spare parts requirements ensures their
acceptance standards or the repair cost exceeds or approaches
availability at the time the planned inspections are performed.
the replacement cost. In other cases, such as first-stage buckets,
Refer to the Reference Drawing Manual provided as part of the
repair options are limited by factors such as irreversible material
comprehensive set of O&M Manuals to aid in identification and
damage. In both cases, users should follow GE recommendations
ordering of gas turbine parts.
regarding replacement or repair of these components.
Additional benefits available from the renewal parts catalog
It should also be recognized that the life consumption of any one
data system are the capability to prepare recommended spare
individual part within a parts set can have variations. This may
parts lists for the combustion, hot gas path and major inspections
lead to a certain percentage of “fallout,” or scrap, of parts being
as well as capital and operational spares.
repaired. Those parts that fallout during the repair process will
Estimated repair and replacement intervals for some of the need to be replaced by new parts. Parts fallout will vary based on
major components are shown in Appendix D. These tables assume the unit operating environment history, the specific part design,
that operation, inspections, and repairs of the unit have been and the current repair technology.
done in accordance with all of the manufacturer’s specifications
and instructions.

28
 New Nozzle
Acceptance Standards

Repaired Nozzle 1st

Nozzle Construction
Min. Acceptance Repair

Repair Cost Exceeds

Replacement Cost
Standard

2nd
Repair

Without Repair 3rd

Repair

Severe Deterioration

10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000

Operating Hours
Figure 38. First-stage nozzle repair program: natural gas fired – continuous dry – base load

Hours/Starts
Type of
hours/ 6B 7E 9E
Type of Inspection starts MS3002K MS5001PA MS5002C, D 6B.03 7E.03 (6)
9E.03 (7)
Combustion (Non-DLN) Factored 12000/400 (3) 12000/800 (1)(3)(5) 12000/800 (1)(3)(5) 12000/600 (2)(5) 8000/900 (2)(5) 8000/900 (2)(5)
Combustion (DLN) Factored 8000/400 (3)(5) 8000/400 (3)(5) 12000/450 (5) 12000/450 (5) 12000/450 (5)
Hot Gas Path Factored 24000/1200 (4) 24000/1200 (4)(5) 24000/1200 (4)(5) 24000/1200 (5) 24000/1200 (5) 24000/900 (5)
Major Actual 48000/2400 48000/2400 (5)
48000/2400 (5)
48000/2400 (5)
48000/2400 (5)
48000/2400 (5)

Hours/Starts
Type of
hours/ 6F 7F 9F
Type of Inspection starts 6F.03 7F.03 7F.04 7FB.01 9F.03 9F.05
Combustion (Non-DLN) Factored 8000/400
Combustion (DLN) Factored 12000/450 (5) 24000/900 24000/900 12000/450 24000/900 12000/450
Hot Gas Path Factored 24000/900 24000/900 32000/900 24000/900 24000/900 24000/900
Major Actual 48000/2400 48000/2400 48000/2400 48000/2400 48000/2400 48000/2400
Factors that can reduce 1. Units with Lean Head End liners have a 400-starts combustion inspection Note:
maintenance intervals: interval. Baseline inspection intervals
• Fuel 2. Multiple Non-DLN configurations exist (Standard, MNQC, IGCC). The typical reflect current production
case is shown; however, different quoting limits may exist on a machine and hardware, unless otherwise
• Load setting
hardware basis. Contact a GE service representative for further information. noted, and operation
• Steam/water injection 3. Combustion inspection without transition piece removal. Combustion in accordance with
• Peak load firing inspection with transition pieces removal to be performed every 2 manufacturer specifications.
operation combustion inspection intervals. They represent initial
• Trips 4. Hot gas path inspection for factored hours eliminated on units that operate recommended intervals in
• Start cycle on natural gas fuel without steam or water injection. the absence of operating
5. Upgraded technology (Extendor*, PIP, etc) may have longer inspection and condition experience.
• Hardware design
intervals.
• Off-frequency operation 6. Also applicable to 7121(EA) models. For Repair/Replace intervals
7. Applicable to non-AGP units only. see Appendix D.
*Trademark of General Electric Company

Figure 39. Baseline recommended inspection intervals: base load – natural gas fuel – dry

GE Power & Water | GER-3620M (05/14) 29

Inspection Intervals “Gas Turbine Design Maintenance Features.” Such inspections
may identify additional areas to be addressed at a future
In the absence of operating experience and resulting part
scheduled maintenance outage, assist with parts or resource
conditions, Figure 39 lists the recommended combustion, hot
planning, or indicate the need to change the timing of a future
gas path and major inspection intervals for current production
outage. The BI should use all the available access points to verify
GE turbines operating under typical conditions of natural gas fuel,
the condition of the internal hardware. As much of the Major
base load, and no water/steam injection. These recommended
Inspection workscope as possible should be done using this visual
intervals represent factored hours or starts calculated using
inspection without dissassembly. Refer to Figure 4 for standard
maintenance factors to account for application specific operating
recommended BI frequency. Specific concerns may warrant
conditions. Initially, recommended intervals are based on
subsequent BIs in order to operate the unit to the next scheduled
the expected operation of a turbine at installation, but this
outage without teardown.
should be reviewed and adjusted as operating and maintenance
data are accumulated. While reductions in the recommended Combustion Inspection Interval
intervals will result from the factors described previously or Equations have been developed that account for the earlier
unfavorable operating experience, increases in the recommended mentioned factors affecting combustion maintenance intervals.
intervals may also be considered where operating experience These equations represent a generic set of maintenance factors
has been favorable. that provide guidance on maintenance planning. As such, these
The condition of the combustion and hot gas path parts provides a equations do not represent the specific capability of any given
basis for customizing a program for inspection and maintenance. combustion system. For combustion parts, the baseline operating
The condition of the compressor and bearing assemblies is the conditions that result in a maintenance factor of one are normal
key driver in planning a major inspection. Historical operation fired startup and shutdown (no trip) to base load on natural gas
and machine conditions can be used to tailor maintenance fuel without steam or water injection.
programs such as optimized repair and inspection criteria to An hours-based combustion maintenance factor can be determined
specific sites/machines. GE leverages these principles and from the equations given in Figure 40 as the ratio of factored hours
accumulated site and fleet experience in a “Condition Based to actual operating hours. Factored hours considers the effects of
Maintenance” program as the basis for maintenance of units fuel type, load setting, and steam/water injection. Maintenance
under Contractual Service Agreements. This experience was factors greater than one reduce recommended combustion
accumulated on units that operate with GE approved repairs, inspection intervals from those shown in Figure 39 representing
field services, monitoring, and full compliance to GE’s technical baseline operating conditions. To obtain a recommended
recommendations. inspection interval for a specific application, the maintenance
GE can assist operators in determining the appropriate factor is divided into the recommended baseline inspection interval.
maintenance intervals for their particular application. Equations A starts-based combustion maintenance factor can be determined
have been developed that account for the factors described earlier from the equations given in Figure 41 and considers the effect of
and can be used to determine application-specific combustion, fuel type, load setting, peaking-fast starts, trips, and steam/water
hot gas path, and major inspection intervals. injection. An application-specific recommended inspection interval
can be determined from the baseline inspection interval in Figure 39
Borescope Inspection Interval
and the maintenance factor from Figure 41. Appendix B shows six
In addition to the planned maintenance intervals, which
example maintenance factor calculations using the above hours
undertake scheduled inspections or component repairs or
and starts maintenance factor equations.
replacements, borescope inspections should be conducted to
identify any additional actions, as discussed in the sections

30
Syngas units require unit-specific intervals to account for unit- Starts-Based Combustion Inspection
specific fuel constituents and water/steam injection schedules.
Baseline CI (Figure 44)
As such, the combustion inspection interval equations may not Maintenance Interval =
Maintenance Factor
apply to those units.
Factored Starts
Maintenance Factor =
Hours-Based Combustion Inspection Actual Starts

Baseline CI (Figure 44) Factored Starts = ∑ (Ki · Afi · Ati · Api · Asi · Ni ), i = 1 to n Start/Stop Cycles
Maintenance Interval =
Maintenance Factor Actual Starts = ∑ (Ni ), i = 1 to n in Start/Stop Cycles

Factored Hours Where:

Maintenance Factor = i = Discrete Start/Stop Cycle (or Operating Practice)
Actual Hours
Ni = Start/Stop Cycles in a Given Operating Mode
Factored Hours = ∑ (Ki · Afi · Api · ti ), i = 1 to n in Operating Modes
Asi = Start Type Severity Factor
Actual Hours = ∑ (ti ), i = 1 to n in Operating Modes As = 1.0 for Normal Start
Where: As = For Peaking-Fast Start See Figure 14
i = Discrete Operating mode (or Operating Practice Api = Load Severity Factor
of Time Interval) Ap = 1.0 up to Base Load
ti = Operating hours at Load in a Given Operating mode Ap = exp (0.009 x Peak Firing Temp Adder in °F)
Api = Load Severity factor for Peak Load
Ap = 1.0 up to Base Load Ati = Trip Severity Factor
Ap = For Peak Load Factor See Figure 11 At = 0.5 + exp(0.0125*%Load) for Trip
Afi = Fuel Severity Factor Afi = Fuel Severity Factor
Af = 1.0 for Natural Gas Fuel (1) Af = 1.0 for Natural Gas Fuel
Af = 1.5 for Distillate Fuel, Non-DLN (2.5 for DLN) Af = 1.25 for Non-DLN (or 1.5 for DLN) for Distillate Fuel
Af = 2.5 for Crude (Non-DLN) Af = 2.0 for Crude (Non-DLN)
Af = 3.5 for Residual (Non-DLN) Af = 3.0 for Residual (Non-DLN)
Ki = Water/Steam Injection Severity Factor Ki = Water/Steam Injection Severity Factor
(% Steam Referenced to Compressor Inlet Air Flow, (% Steam Referenced to Compressor Inlet Air Flow,
w/f = Water to Fuel Ratio) w/f = Water to Fuel Ratio)
K = Max(1.0, exp(0.34(%Steam – 2.00%))) K = Max(1.0, exp(0.34(%Steam – 1.00%)))
for Steam, Dry Control Curve for Steam, Dry Control Curve
K = Max(1.0, exp(0.34(%Steam – 1.00%))) K = Max(1.0, exp(0.34(%Steam – 0.50%)))
for Steam, Wet Control Curve for Steam, Wet Control Curve
K = Max(1.0, exp(1.80(w/f – 0.80))) K = Max(1.0, exp(1.80(w/f – 0.40)))
for Water, Dry Control Curve for Water, Dry Control Curve
K = Max(1.0, exp(1.80(w/f – 0.40))) K = Max(1.0, exp(1.80(w/f – 0.20)))
for Water, Wet Control Curve for Water, Wet Control Curve
(1) Af = 10 for DLN 1/DLN 1+ extended lean-lean, and DLN 2.0/ DLN 2+
extended piloted premixed operating modes. Figure 41. Combustion inspection starts-based maintenance factors

Figure 40. Combustion inspection hours-based maintenance factors

GE Power & Water | GER-3620M (05/14) 31

Hot Gas Path Inspection Interval The starts-based hot gas path criterion is determined from the
The hours-based hot gas path criterion is determined from the equations given in Figure 43.
equations given in Figure 42. With these equations, a maintenance As previously described, the limiting criterion (hours or starts)
factor is determined that is the ratio of factored operating hours determines the maintenance interval. Examples of these equations
and actual operating hours. The factored hours consider the are in Appendix A.
specifics of the duty cycle relating to fuel type, load setting and
steam or water injection. Maintenance factors greater than one Starts-Based HGP Inspection
reduce the hot gas path inspection interval from the baseline Maintenance Interval = S
(typically 24,000 hour) case. To determine the application specific (Starts) Maintenance Factor
maintenance interval, the maintenance factor is divided into the
Where:
baseline hot gas path inspection interval, as shown in Figure 42. Factored Starts
Maintenance Factor =
Actual Starts
Hours-Based HGP Inspection
Factored Starts = 0.5NA + NB + 1.3NP + PsF + ∑ni=1 (aTi – 1) Ti
Maintenance Interval = Baseline HGPI (Figure 39)
(Hours) Maintenance Factor Actual Starts = (NA + NB + NP)
S = Baseline Starts-Based Maintenance Interval (Figure 39)
Factored Hours
Maintenance Factor = NA = Annual Number of Part Load Start/Stop Cycles
Actual Hours
(<60% Load)
Factored Hours = ∑ni=1 (Si · Afi · Api · ti )
NB = Annual Number of Base Load Start/Stop Cycles
Actual Hours = ∑ni=1 (ti )
NP = Annual Number of Peak Load Start/Stop Cycles
i = 1 to n discrete operating modes (or operating practices (>100% Load)
of time interval)
Ps = Peaking-Fast Start Factor (See Figure 14)
ti = Fired hours in a given operating mode
F = Annual Number of Peaking-Fast Starts
Api = Load severity factor for given operating mode
Ap = 1.0 up to base load T = Annual Number of Trips
Ap = For peak load factor see Figure 11. aT = Trip Severity Factor = f(Load) (See Figure 20)
Afi = Fuel severity factor for given operating mode n = Number of Trip Categories (i.e. Full Load, Part Load, etc.)
Af = 1.0 for natural gas
Af = 1.5 for distillate Figure 43. Hot gas path maintenance interval: starts-based criterion
(=1.0 when Ap > 1, at minimum Af ∙ Ap = 1.5)
Af = 2 to 3 for crude Rotor Inspection Interval
Af = 3 to 4 for residual Like hot gas path components, the unit rotor has a maintenance
Si = Water/steam injection severity factor = Ki + (Mi ∙ Ii) interval involving removal, disassembly, and inspection. This
I = Percent water/steam injection referenced interval indicates the serviceable life of the rotor and is generally
to compressor inlet air flow considered to be the teardown inspection and repair/replacement
M&K = Water/steam injection constants
interval for the rotor. The disassembly inspection is usually
M K Control Steam Injection S2N/S3N Material concurrent with a hot gas path or major inspection; however,
0 1 Dry <2.2% All it should be noted that the maintenance factors for rotor
0 1 Dry >2.2% Non-FSX-414
maintenance intervals are distinct from those of combustion and
0.18 0.6 Dry >2.2% FSX-414
hot gas path components. As such, the calculation of consumed
0.18 1 Wet >0% Non-FSX-414
life on the rotor may vary from that of combustion and hot gas
0.55 1 Wet >0% FSX-414
path components. Customers should contact GE when their rotor is
Figure 42. Hot gas path maintenance interval: hours-based criterion
approaching the end of its serviceable life for technical advisement.

32
Figure 44 describes the procedure to determine the hours- maintenance factor. The rotor starts-based maintenance interval
based maintenance criterion. Peak load operation is the primary is determined by dividing the baseline rotor maintenance interval
maintenance factor for the F-class rotor and will act to increase of 5000 starts by the calculated maintenance factor. The baseline
the hours-based maintenance factor and to reduce the rotor rotor maintenance interval is also the maximum interval, since
maintenance interval. For B/E-class units time on turning gear also calculated maintenance factors less than one are not considered.
affects rotor life.
When the rotor reaches the earlier of the inspection intervals
The starts-based rotor maintenance interval is determined from the described in Figures 44 and 45, an unstack of the rotor is required
equations given in Figure 45. Adjustments to the rotor maintenance so that a complete inspection of the rotor components in both
interval are determined from rotor-based operating factors as the compressor and turbine can be performed. It should be
described previously. In the calculation for the starts-based rotor expected that some rotor components will either have reached
maintenance interval, equivalent starts are determined for cold, the end of their serviceable life or will have a minimal amount of
warm, and hot starts over a defined time period by multiplying residual life remaining and will require repair or replacement at this
the appropriate cold, warm, and hot start operating factors by the inspection point. Depending on the extent of refurbishment and
number of cold, warm, and hot starts respectively. Additionally, part replacement, subsequent inspections may be required at a
equivalent starts for trips from load are added. The total equivalent reduced interval.
starts are divided by the actual number of starts to yield the

Hours-Based Rotor Inspection Starts-Based Rotor Inspection

Maintenance Interval = R Maintenance Interval = 5,000(1)

(Hours) Maintenance Factor (Starts) Maintenance Factor

Factored Hours H + 2P(1) MF for H + 2P + 2TG(2) Factored Starts

MF = = = Maintenance Factor =
Actual Hours H+P B/E-class H+P Actual Starts

H = Non-peak load operating hours For units with published start factors:

Maintenance (Fh1 · Nh1 + Fh2 · Nh2 + Fw1 · Nw1 + Fw2 · Nw2 + Fc · Nc + Ft · Nt)
P = Peak load operating hours =
Factor (N +N +N +N +N )
h1 h2 w1 w2 c

TG = Hours on turning gear For B/E-class units

NS + NT
R = Baseline rotor inspection interval Maintenance Factor =
NS
Machine R (3)
For all other units additional start factors may apply.
F-class 144,000
Number of Starts Start Factors (2)
All other 200,000
Nh1 = Number of hot 1 starts Fh1 = Hot 1 start factor (down 0-1 hr)

(1) Maintenance factor equation to be used unless otherwise notified in unit- Nh2 = Number of hot 2 starts Fh2 = Hot 2 start factor (down 1-4 hr)
specific documentation. Nw1 = Number of warm 1 starts Fw1 = Warm 1 start factor (down 4-20 hr)
(2) To diminish potential turning gear impact, major inspections must include Nw2 = Number of warm 2 starts Fw2 = Warm 2 start factor (down 20-40 hr)
a thorough visual and dimensional examination of the hot gas path Nc = Number of cold starts Fc = Cold start factor (down >40 hr)
turbine rotor dovetails for signs of wearing, galling, fretting, or cracking. Nt = Number of trips from load Ft = Trip from load factor
If no distress is found during inspection or after repairs are performed to
Ns = Total number of fired starts
the dovetails, time on turning gear may be omitted from the hours-based
maintenance factor. (1) Baseline rotor inspection interval is 5,000 fired starts unless otherwise
(3) Baseline rotor inspection intervals to be used unless otherwise notified in notified in unit-specific documentation.
unit-specific documentation. (2) Start factors for certain F-class units are tabulated in Figure 22. For all
other machines, consult unit-specific documentation to determine if start
Figure 44. Rotor maintenance interval: hours-based criterion factors apply.

Figure 45. Rotor maintenance interval: starts-based criterion

GE Power & Water | GER-3620M (05/14) 33

The baseline rotor life is predicated upon sound inspection results Precise estimates of the outage duration, resource requirements,
at the major inspections. For F-class rotors the baseline intervals critical-path scheduling, recommended replacement parts, and
are typically 144,000 hours and 5,000 starts. For rotors other than costs associated with the inspection of a specific installation may
F-class, the baseline intervals are typically 200,000 hours and be sourced from the local GE field services office.
5,000 starts. Consult unit-specific documentation to determine if
alternate baseline intervals or maintenance factors may apply. Conclusion
GE heavy-duty gas turbines are designed to have high availability.
Personnel Planning To achieve maximum gas turbine availability, an owner must
It is essential that personnel planning be conducted prior to an understand not only the equipment but also the factors affecting
outage. It should be understood that a wide range of experience, it. This includes the training of operating and maintenance
productivity, and working conditions exist around the world. personnel, following the manufacturer’s recommendations, regular
However, an estimate can be made based upon maintenance periodic inspections, and the stocking of spare parts for immediate
inspection labor assumptions, such as the use of a crew of replacement. The recording and analysis of operating data is also
workers with trade skill (but not necessarily direct gas turbine essential to preventative and planned maintenance. A key factor
experience), with all needed tools and replacement parts (no in achieving this goal is a commitment by the owner to provide
repair time) available. These estimated craft labor hours should effective outage management, to follow published maintenance
include controls/accessories and the generator. In addition to instructions, and to utilize the available service support facilities.
the craft labor, additional resources are needed for technical
It should be recognized that, while the manufacturer provides
direction, specialized tooling, engineering reports, and site
general maintenance recommendations, it is the equipment
mobilization/demobilization.
user who controls the maintenance and operation of equipment.
Inspection frequencies and the amount of downtime varies Inspection intervals for optimum turbine service are not fixed for
within the gas turbine fleet due to different duty cycles and the every installation but rather are developed based on operation
economic need for a unit to be in a state of operational readiness. and experience. In addition, through application of a Contractual
Contact your local GE service representative for the estimated Service Agreement to a particular turbine, GE can work with
labor hours and recommended crew size for your specific unit. a user to establish a maintenance program that may differ
from general recommendations but will be consistent with
Depending upon the extent of work to be done during each
contractual responsibilities.
maintenance task, a cooldown period of 4 to 24 hours may be
required before service may be performed. This time can be The level and quality of a rigorous maintenance program have a
utilized productively for job move-in, correct tagging and locking direct effect on equipment reliability and availability. Therefore,
equipment out-of-service, and general work preparations. At the a rigorous maintenance program that reduces costs and outage
conclusion of the maintenance work and systems check out, a time while improving reliability and earning ability is the optimum
turning gear time of two to eight hours is normally allocated prior GE gas turbine user solution.
to starting the unit. This time can be used for job clean-up and
preparing for start.

Local GE field service representatives are available to help plan

maintenance work to reduce downtime and labor costs. This
planned approach will outline the replacement parts that may be
needed and the projected work scope, showing which tasks can
be accomplished in parallel and which tasks must be sequential.
Planning techniques can be used to reduce maintenance cost by
optimizing lifting equipment schedules and labor requirements.

34
References
Jarvis, G., “Maintenance of Industrial Gas Turbines,” GE Gas Turbine
State of the Art Engineering Seminar, paper SOA-24-72, June 1972.

Patterson, J. R., “Heavy-Duty Gas Turbine Maintenance Practices,”

GE Gas Turbine Reference Library, GER-2498, June 1977.

Moore, W. J., Patterson, J.R, and Reeves, E.F., “Heavy-Duty Gas

Turbine Maintenance Planning and Scheduling,” GE Gas Turbine
Reference Library, GER-2498; June 1977, GER 2498A, June 1979.

Carlstrom, L. A., et al., “The Operation and Maintenance of General

Electric Gas Turbines,” numerous maintenance articles/authors
reprinted from Power Engineering magazine, General Electric
Publication, GER-3148; December 1978.

Knorr, R. H., and Reeves, E. F., “Heavy-Duty Gas Turbine

Maintenance Practices,” GE Gas Turbine Reference Library, GER-
3412; October 1983; GER- 3412A, September 1984; and GER-3412B,
December 1985.

Freeman, Alan, “Gas Turbine Advance Maintenance Planning,”

paper presented at Frontiers of Power, conference, Oklahoma State
University, October 1987.

Hopkins, J. P, and Osswald, R. F., “Evolution of the Design,

Maintenance and Availability of a Large Heavy-Duty Gas Turbine,”
GE Gas Turbine Reference Library, GER-3544, February 1988 (never
printed).

Freeman, M. A., and Walsh, E. J., “Heavy-Duty Gas Turbine

Operating and Maintenance Considerations,” GE Gas Turbine
Reference Library, GER-3620A.

GEI-41040, “Fuel Gases for Combustion in Heavy-Duty Gas

Turbines.”

GEI-41047, “Gas Turbine Liquid Fuel Specifications.”

GEK-101944, “Requirements for Water/Steam Purity in Gas

Turbines.”

GER-3419A, “Gas Turbine Inlet Air Treatment.”

GER-3569F, “Advanced Gas Turbine Materials and Coatings.”

GEK-32568, “Lubricating Oil Recommendations for Gas Turbines

with Bearing Ambients Above 500°F (260°C).”

GEK-110483, “Cleanliness Requirements for Power Plant Installation,

Commissioning and Maintenance.”

GE Power & Water | GER-3620M (05/14) 35

Appendix Therefore, the steam severity factor for modes 1, 2, and 3 are
= S1 = S2 = S3 = K + (M ∙ I) = 1
A.1) Example 1 – Hot Gas Path Maintenance
Interval Calculation From the hours-based criteria, the maintenance factor is
A 7E.03 user has accumulated operating data since the last hot determined from Figure 42.
gas path inspection and would like to estimate when the next ∑ni=1 (Si · Afi · Api · ti )
MF =
one should be scheduled. The user is aware from GE publications ∑ni=1) (ti )
that the baseline HGP interval is 24,000 hours if operating on
(1 · 1 · 1 · 3200) + (1 · 1.5 · 1 · 350) + (1 · 1 · 6 · 120) + (2.3 · 1 · 1 · 20)
natural gas, with no water or steam injection, and at base load. =
(3200 + 350 + 120 + 20)
It is also understood that the baseline starts interval is 1200,
MF = 1.22
based on normal startups, no trips, no peaking-fast starts. The
actual operation of the unit since the last hot gas path inspection The hours-based adjusted inspection interval is therefore,
is much different from the baseline case. The unit operates in four Adjusted Inspection Interval = 24,000/1.22 = 19,700 hours
different operating modes:
[Note, since total annual operating hours is 3690, the estimated
1. The unit runs 3200 hrs/yr in its first operating mode, which is time to reach 19,700 hours is 19,700/3690 = 5.3 years.]
natural gas at base or part load with no steam/water injection.
Also, since the last hot gas path inspection the unit has averaged
2. The unit runs 350 hrs/yr in its second operating mode, which is 145 normal start-stop cycles per year, 5 peaking-fast start cycles
distillate fuel at base or part load with no steam/water injection. per year, and 20 base load cycles ending in trips (aT = 8) per year.
The starts-based hot gas path maintenance interval parameters
3. The unit runs 120 hrs/yr in its third operating mode, which is
for this unit are summarized below:
natural gas at peak load (+100°F) with no steam/water injection.
Normal Peaking Cycles ending
4. The unit runs 20 hrs/yr in its fourth operating mode, which is Total
cycles starts, °F in trip, T
natural gas at base load with 2.4% steam injection on a wet
Part load cycles, NA 40 0 0 40
control curve.
Base load cycles, NB 100 5 20 125
The hours-based hot gas path maintenance interval parameters Peak load cycles, NP 5 0 0 5
for these four operating modes are summarized below:
From the starts-based criteria, the maintenance factor is
Operating Mode (i) determined from Figure 43.
1 2 3 4
0.5NA + NB + 1.3NP + PsF + ∑ni=1 (aTi - 1) Ti
Fired hours (hrs/yr) t 3200 350 120 20 MF =
NA + NB + NP
Fuel severity factor Af 1 1.5 1 1
0.5 (40) + 125 + 1.3 (5) + 3.5 (5) + (8 - 1 )20
Load severity factor Ap 1 1 [e (0.018*100)] = 6 1 MF =
40 + 125 + 5
Steam/water injection rate (%) I 0 0 0 2.4
MF = 1.8
For this particular unit, the second- and third-stage nozzles are The adjusted inspection interval based on starts is
FSX-414 material. From Figure 42, at a steam injection rate of 2.4%
Adjusted Inspection Interval = 1200/1.8 = 667 starts
on a wet control curve,
[Note, since the total annual number of starts is 170, the estimated
M4 = 0.55, K4 = 1
time to reach 667 starts is 667/170 = 3.9 years.]
The steam severity factor for mode 4 is therefore,
In this case the unit would reach the starts-based hot gas path
= S4 = K4 + (M4 ∙ I4) = 1 + (0.55 ∙ 2.4) = 2.3
interval prior to reaching the hours-based hot gas path interval.
At a steam injection rate of 0%, The hot gas path inspection interval for this unit is therefore 667
M = 0, K = 1 starts (or 3.9 years).

36
A.2) Example 2 – Hot Gas Path Factored Total Trips
Starts Calculation 5. 50% load (aT1 = 6.5), T1 = 5 + 1 = 6
A 7E.03 user has accumulated operating data for the past year of
6. Base load (aT2 = 8), T2 = 35 + 2 = 37
operation. This data shows number of trips from part, base, and
7. Peak load (aT3 = 10), T3 = 10
peak load, as well as peaking-fast starts. The user would like to
calculate the total number of factored starts in order to plan the Additional Cycles
next HGP outage. Figure 43 is used to calculate the total number of Peaking-fast starts, F = 7
factored starts as shown below.
From the starts-based criteria, the total number of factored starts
Operational history: (FS) and actual starts (AS) is determined from Figure 43.
Peaking
Peaking Normal
Normal starts with
cycles normal
starts with starts with Total FS = 0.5NA + NB + 1.3NP + PsF + ∑ni=1 (aTi - 1) Ti
trips trips
shutdowns
= 0.5 · 41 + 66 + 1.3 · 50 + 3.5 · 7 + (6.5 - 1) 6 + (8 - 1) 37 + (10 - 1) 10 = 558
Part load
35 0 1 5 41
cycles, NA
AS = NA + NB + NP = 41 + 66 + 50 = 157
Base load
25 4 2 35 66
cycles, NB FS 558
Maintenance Factor = = = 3.6
Peak load AS 157
40 0 0 10 50
cycles, NP

GE Power & Water | GER-3620M (05/14) 37

B) Examples – Combustion Maintenance
Interval Calculations
(reference Figures 40 and 41)
DLN 1 Peak Load with Power Augmentation Standard Combustor Base Load on Crude Oil
+50F Tfire Increase Natural Gas Fuel No Tfire Increase Crude Oil Fuel
3.5% Steam Augmentation 6 Hours/Start 1.0 Water/Fuel Ratio 220 Hours/Start
Peaking Start Wet Control Curve Normal Start Dry Control Curve
Normal Shutdown (No Trip) Normal Shutdown (No Trip)
Factored Hours = Ki * Afi * Api * ti = 34.5 Hours Factored Hours = Ki * Afi * Api * ti = 788.3 Hours
Hours Maintenance Factor = (34.5/6) 5 .8 Hours Maintenance Factor = (788.3/220) 3 .6
Where Ki = 2.34 Max(1.0, exp(0.34(3.50-1.00))) Wet Where Ki = 1.43 Max(1.0, exp(1.80(1.00-0.80))) Dry
Afi = 1.00 Natural Gas Fuel Afi = 2.50 Crude Oil, Std (Non-DLN)
Api = 2.46 exp(0.018(50)) Peak Load Api = 1.00 Base Load
ti = 6.0 Hours/Start ti = 220.0 Hours/Start
Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 17.4 Starts Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 5.9 Starts
Starts Maintenance Factor = (17.4/1) 17 .4 Starts Maintenance Factor = (5.9/1) 5 .9
Where Ki = 2.77 Max(1.0, exp(0.34(3.50-0.50))) Wet Where Ki = 2.94 Max(1.0, exp(1.80(1.00-0.40))) Dry
Afi = 1.00 Natural Gas Fuel Afi = 2.00 Crude Oil, Std (Non-DLN)
Ati = 1.00 No Trip at Load Ati = 1.00 No Trip at Load
Api = 1.57 exp(0.009(50)) Peak Load Api = 1.00 Base Load
Asi = 4.0 Peaking Start Asi = 1.00 Normal Start
Ni = 1.0 Considering Each Start Ni = 1.0 Considering Each Start

DLN 2 .6 Base Load on Distillate DLN 2 .6 Base Load on Natural Gas with Trip @ Load
No Tfire Increase Distillate Fuel No Tfire Increase Natural Gas Fuel
1.1 Water/Fuel Ratio 220 Hours/Start No Steam/Water Injection 168 Hours/Start
Normal Start Dry Control Curve Normal Start Dry Control Curve
Normal Shutdown (No Trip) Trip @ 60% Load
Factored Hours = Ki * Afi * Api * ti = 943.8 Hours Factored Hours = Ki * Afi * Api * ti = 168.0 Hours
Hours Maintenance Factor = (943.8/220) 4 .3 Hours Maintenance Factor = (168.0/168) 1 .0
Where Ki = 1.72 Max(1.0, exp(1.80(1.10-0.80))) Dry Where Ki = 1.00 No Injection
Afi = 2.50 Distillate Fuel, DLN Afi = 1.00 Natural Gas Fuel
Api = 1.00 Base Load Api = 1.00 Base Load
ti = 220.0 Hours/Start ti = 168.0 Hours/Start
Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 5.3 Starts Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 2.6 Starts
Starts Maintenance Factor = (5.3/1) 5 .3 Starts Maintenance Factor = (2.6/1) 2 .6
Where Ki = 3.53 Max(1.0, exp(1.80(1.10-0.40))) Dry Where Ki = 1.00 No Injection
Afi = 1.50 Distillate Fuel, DLN Afi = 1.00 Natural Gas Fuel
Ati = 1.00 No Trip at Load Ati = 2.62 0.5+exp(0.0125*60) for Trip
Api = 1.00 Base Load Api = 1.00 Base Load
Asi = 1.00 Normal Start Asi = 1.00 Normal Start
Ni = 1.0 Considering Each Start Ni = 1.0 Considering Each Start

DLN 1 Combustor Base Load on Distillate DLN 2 .6 Peak Load on Natural Gas with Peaking Start
No Tfire Increase Distillate Fuel +35F Tfire Increase Natural Gas Fuel
0.9 Water/Fuel Ratio 500 Hours/Start 3.5% Steam Augmentation 4 Hours/Start
Normal Start Dry Control Curve Peaking Start Dry Control Curve
Normal Shutdown (No Trip) Normal Shutdown (No Trip)
Factored Hours = Ki * Afi * Api * ti = 1496.5 Hours Factored Hours = Ki * Afi * Api * ti = 12.5Hours
Hours Maintenance Factor = (1496.5/500) 3 .0 Hours Maintenance Factor = (12.5/4) 3 .1
Where Ki = 1.20 Max(1.0, exp(1.80(0.90-0.80))) Dry Where Ki = 1.67 Max(1.0, exp(0.34(3.50-2.00)))
Afi = 2.50 Distillate Fuel, DLN 1 Afi = 1.00 Natural Gas Fuel
Api = 1.00 Part Load Api = 1.88 exp(0.018(35)) Peak Load
ti = 500.0 Hours/Start ti = 4.0 Hours/Start
Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 3.7 Starts Factored Starts = Ki * Afi * Ati * Api * Asi * Ni = 12.8 Starts
Starts Maintenance Factor = (3.7/1) 3 .7 Starts Maintenance Factor = (12.8/1) 12 .8
Where Ki = 2.46 Max(1.0, exp(1.80(0.90-0.40))) Dry Where Ki = 2.34 Max(1.0, exp(0.34(3.50-1.00))) Dry
Afi = 1.50 Distillate Fuel, DLN Afi = 1.00 Natural Gas Fuel
Ati = 1.00 No Trip at Load Ati = 1.00 No Trip at Load
Api = 1.00 Part Load Api = 1.37 exp(0.009(35)) Peak Load
Asi = 1.00 Normal Start Asi = 4.0 Peaking Start
Ni = 1.0 Considering Each Start Ni = 1.0 Considering Each Start

38
C) Definitions Equivalent Availability: Probability of a multi-shaft
Reliability: Probability of not being forced out of combined-cycle power plant being available for power
service when the unit is needed — includes forced generation — independent of whether the unit is
outage hours (FOH) while in service, while on needed — includes all unavailable hours — includes
reserve shutdown and while attempting to start the effect of the gas and steam cycle MW output
normalized by period hours (PH) — units are %. contribution to plant output; units are %.

Equivalent Availability =
Reliability = (1-FOH/PH) (100)
FOH = total forced outage hours GT UH HRSG UH ST UH
[1 – +B + x 100 ]
PH = period hours GT PH GT PH ST PH

GT UH = Gas Turbine Unavailable Hours

Availability: Probability of being available,
GT PH = Gas Turbine Period Hours
independent of whether the unit is needed – includes
HRSG UH = HRSG Total Unavailable Hours
all unavailable hours (UH) – normalized by period
hours (PH) – units are %: ST UH = Steam Turbine Unavailable Hours

Availability = (1-UH/PH) (100) ST PH = Steam Turbine Period Hours

UH = total unavailable hours (forced outage, B = Steam Cycle MW Output

failure to start, scheduled maintenance Contribution (normally 0.30)

hours, unscheduled maintenance hours)

MTBF–Mean Time Between Failure: Measure of
PH = period hours probability of completing the current run. Failure
events are restricted to forced outages (FO) while in
Equivalent Reliability: Probability of a multi-shaft service – units are operating hours.
combined-cycle power plant not being totally forced
MTBF = OH/FO
out of service when the unit is required includes the
effect of the gas and steam cycle MW output OH = Operating Hours

contribution to plant output – units are %. FO = Forced Outage Events from a Running
(On-line) Condition
Equivalent Reliability =

GT FOH HRSG FOH ST FOH Service Factor: Measure of operational use, usually
[1 – +B + x 100 ] expressed on an annual basis – units are %.
GT PH B PH ST PH
SF = OH/PH x 100
GT FOH = Gas Turbine Forced Outage Hours OH = Operating Hours on an annual basis
GT PH = Gas Turbine Period Hours PH = Period Hours (8760 hours per year)

HRSG FOH = HRSG Forced Outage Hours

Operating Duty Definition:
B PH = HRSG Period Hours Duty Service Factor Fired Hours/Start
ST FOH = Steam Turbine Forced Outage Hours Stand-by < 1% 1 to 4

ST PH = Steam Turbine Period Hours Peaking 1% – 17% 3 to 10

Cycling 17% – 50% 10 to 50
B = Steam Cycle MW Output
Continuous > 90% >> 50
Contribution (normally 0.30)

GE Power & Water | GER-3620M (05/14) 39

D) Estimated Repair and Replacement Intervals
(Natural Gas Only)
Repair/replace intervals reflect current production hardware, unless 6B.03
otherwise noted, and operation in accordance with manufacturer Repair Interval Replace Interval (Hours) Replace Interval (Starts)
specifications. Consult previous revisions of GER 3620 or other unit- Combustion Liners Cl 4 (Cl) 4 (Cl) / 5 (Cl)(1)

specific documentation for estimated repair/replacement intervals Caps Cl 4 (Cl) 5 (Cl)

Transition Pieces Cl 4 (Cl) 4 (Cl) / 5 (Cl)(1)
of previous generation gas turbine models and hardware. Consult
Fuel Nozzles Cl 2 (Cl) 2 (Cl) / 3 (Cl)(4)
your GE service representative for further information. Crossfire Tubes Cl 1 (CI) 1 (CI)
Crossfire Tube CI 1 (CI) 1 (CI)
MS3002K Parts Retaining Clips
Repair Interval Replace Interval (Hours) Replace Interval (Starts) Flow Divider Cl 3 (Cl) 3 (Cl)
Combustion Liners CI 4 (CI) 4 (CI) (Distillate)
Transition Pieces CI(1) 4 (CI) 4 (CI) Fuel Pump Cl 3 (Cl) 3 (Cl)
(Distillate)
Stage 1 Nozzles (HGPI)(2) 4 (HGPI) 2 (HGPI)
Stage 2 Nozzles (HGPI)(2) 4 (HGPI) 4 (HGPI) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI)

Stage 1 Shrouds (HGPI)(2) 4 (HGPI) 4 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI)

Stage 2 Shrouds (HGPI)(2) 4 (HGPI) 4 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI)

Stage 1 Buckets – (3) 2 (HGPI)(3) 2 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 2 (HGPI)

Stage 2 Buckets (HGPI)(2) 4 (HGPI) 4 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI)
Note: Repair/replace intervals reflect current production hardware, unless otherwise noted, and operation in Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI)
accordance with manufacturer specifications. They represent initial recommended intervals in the absence of Stage 1 Buckets HGPI 3 (HGPI)(2) 3 (HGPI)
operating and condition experience. For factored hours and starts of the repair intervals, refer to Figure 39.
Stage 2 Buckets HGPI 3 (HGPI)(3) 4 (HGPI)
CI = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval Stage 3 Buckets HGPI 3 (HGPI) 4 (HGPI)
(1) Repair interval is every 2 combustion inspection intervals. Note: Repair/replace cycles reflect current production (6B.03) hardware, unless otherwise noted, and operation
(2) Repair interval is every 2 hot gas path inspection intervals with the exception of 1st stage nozzle in accordance with manufacturer specifications. They represent initial recommended intervals in the absence
start-based repair interval where repair interval is one inspection interval. of operating and condition experience. For factored hours and starts of the repair intervals, refer to Figure 39.
(3) No repair required. GE approved repair at 24,000 factored hours may extend replace interval to Cl = Combustion Inspection Interval
72000 factored hours. HGPI = Hot Gas Path Inspection Interval
(1) 4 (CI) for non-DLN / 5 (CI) for DLN
Figure D-1. Estimated repair and replacement intervals
(2) 3 (HGPI) with strip and recoat at first HGPI
(3) 3 (HGPI) for current design only. Consult your GE Energy representative for replace intervals by part number.
(4) 2 (CI) for non-DLN / 3 (CI) for DLN
MS5001PA / MS5002C,D Parts
Figure D-3. Estimated repair and replacement intervals
Repair Interval Replace Interval (Hours) Replace Interval (Starts)
Combustion Liners CI 4 (CI) 3 (CI)
Transition Pieces CI(1) 4 (CI) 4 (CI)(5)
Stage 1 Nozzles HGPI(2) 4 (HGPI) 2 (HGPI)
Stage 2 Nozzles HGPI(2) 4 (HGPI) 4 (HGPI)
Stage 1 Shrouds HGPI(2) 4 (HGPI) 4 (HGPI)
Stage 2 Shrouds – (3) 4 (HGPI) 4 (HGPI)
Stage 1 Buckets – (4) 2 (HGPI)(4) 2 (HGPI)
Stage 2 Buckets HGPI(2) 4 (HGPI) 4 (HGPI)
Note: Repair/replace cycles reflect current production hardware, unless otherwise noted, and operation in
accordance with manufacturer specifications. They represent initial recommended intervals in the absence of
operating and condition experience. For factored hours and starts of the repair intervals, refer to Figure 39.
CI = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval
(1) Repair interval is every 2 combustion inspection intervals.
(2) Repair interval is every 2 hot gas path inspection intervals with the exception of 1st stage nozzle start-
based repair interval where repair interval is one inspection interval.
(3) No repair required
(4) No repair required. GE approved repair at 24,000 factored hours may extend replace interval to 72000
factored hours
(5) 6 replace intervals (starts-based) for DLN and lean head end (LHE) units.

Figure D-2. Estimated repair and replacement intervals

40
7E.03 (7) 9E.03 (6)
Repair Interval Replace Interval (Hours) Replace Interval (Starts) Repair Interval Replace Interval (Hours) Replace Interval (Starts)
Combustion Liners Cl 3 (Cl) / 5 (Cl)(1) 5 (Cl) Combustion Liners Cl 3 (Cl) / 5 (Cl)(1) 5 (Cl)
Caps Cl 3 (Cl) 5 (Cl) Caps Cl 3 (Cl) 5 (Cl)
Transition Pieces Cl 4 (Cl) / 6 (Cl)(5) 6 (Cl) Transition Pieces Cl 4 (Cl) / 6 (Cl)(4) 6 (Cl)
Fuel Nozzles Cl 2 (Cl) / 3 (Cl)(6) 3 (Cl) Fuel Nozzles Cl 2 (Cl) / 3 (Cl)(5) 3 (Cl)
Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl)
Crossfire Tube CI 1 (CI) 1 (CI) Crossfire Tube CI 1 (CI) 1 (CI)
Retaining Clips Retaining Clips
Flow Divider Cl 3 (Cl) 3 (Cl) Flow Divider Cl 3 (Cl) 3 (Cl)
(Distillate) (Distillate)
Fuel Pump Cl 3 (Cl) 3 (Cl) Fuel Pump Cl 3 (Cl) 3 (Cl)
(Distillate) (Distillate)
Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 3 (HGPI)
Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 4 (HGPI)
Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 4 (HGPI)
Stage 1 Buckets HGPI 3 (HGPl)(2)(3) 3 (HGPI) Stage 1 Buckets HGPI 3 (HGPl)(2) 3 (HGPI)
Stage 2 Buckets HGPI 3 (HGPl)(4) 4 (HGPI) Stage 2 Buckets HGPI 3 (HGPl)(3) 4 (HGPI)
Stage 3 Buckets HGPI 3 (HGPl) 4 (HGPI) Stage 3 Buckets HGPI 3 (HGPl) 4 (HGPI)
Note: Repair/replace intervals reflect current production (7121(EA) or 7E.03) hardware, unless otherwise noted, Note: Repair/replace intervals reflect current production (9171(E)) hardware, unless otherwise noted, and
and operation in accordance with manufacturer specifications. They represent initial recommended intervals operation in accordance with manufacturer specifications. They represent initial recommended intervals in
in the absence of operating and condition experience. For factored hours and starts of the repair intervals, the absence of operating and condition experience. For factored hours and starts of the repair intervals, refer
refer to Figure 39. to Figure 39.
Cl = Combustion Inspection Interval Cl = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval HGPI = Hot Gas Path Inspection Interval
(1) 3 (CI) for DLN / 5 (CI) for non-DLN (1) 3 (CI) for DLN / 5 (CI) for non-DLN
(2) Strip and Recoat is required at first HGPI to achieve 3 HGPI replace interval. (2) Strip and Recoat is required at first HGPI to achieve 3 HGPI replace interval.
(3) Uprated 7E machines (2055 Tfire) require HIP rejuvenation at first HGPI to achieve 3 HGPI replace interval. (3) 3 (HGPI) interval requires meeting tip shroud engagement criteria at prior HGP repair intervals.
(4) 3 (HGPI) interval requires meeting tip shroud engagement criteria at prior HGP repair intervals. Consult your GE service representative for details.
Consult your GE service representative for details. (4) 4 (CI) for DLN / 6 (CI) for non-DLN
(5) 4 (CI) for DLN / 6 (CI) for non-DLN (5) 2 (CI) for DLN / 3 (CI) for non-DLN
(6) 2 (CI) for DLN / 3 (CI) for non-DLN (6) Applicable to non-AGP units only
(7) Also applicable to 7121(EA) models.
Figure D-5. Estimated repair and replacement intervals
Figure D-4. Estimated repair and replacement intervals

GE Power & Water | GER-3620M (05/14) 41

6F.03 7F.04
Repair Interval Replace Interval (Hours) Replace Interval (Starts) Repair Interval Replace Interval (Hours) Replace Interval (Starts)
Combustion Liners CI 2 (CI) 2 (CI) Combustion Liners Cl 2 (Cl) 2 (Cl)
Caps CI 3 (CI) 2 (CI) Caps Cl 2 (Cl) 2 (Cl)
Transition Pieces CI 3 (CI) 2 (CI) Transition Pieces Cl 2 (Cl) 2 (Cl)
Fuel Nozzles CI 2 (CI) 2 (CI) Fuel Nozzles Cl 2 (Cl) 2 (Cl)
Crossfire Tubes CI 1 (CI) 1 (CI) Crossfire Tubes Cl 1 (Cl) 1 (Cl)
Crossfire Tube CI 1 (CI) 1 (CI) Crossfire Tube CI 1 (CI) 1 (CI)
Retaining Clips Retaining Clips
End Covers CI 4 (CI) 2 (CI) End Covers CI 2 (Cl) 2 (Cl)
Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 1 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 4 (HGPI) 4 (HGPI)
Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 1 Shrouds HGPI 3 (HGPI) 3 (HGPI)
Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 3 (HGPI) 3 (HGPI)
Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGP)
Stage 1 Buckets HGPI 3 (HGPI) 2 (HGPI) Stage 1 Buckets HGPI 3 (HGPI) 3 (HGPI)
Stage 2 Buckets HGPI 3 (HGPI) 2 (HGPI) Stage 2 Buckets HGPI 3 (HGPI) 3 (HGPI)
Stage 3 Buckets HGPI 2 (HGPI) 3 (HGPI) Stage 3 Buckets HGPI 3 (HGPI) 3 (HGPI)
Note: Repair/replace intervals reflect current production (6F.03 DLN 2.6) hardware, unless otherwise noted, Note: Repair/replacement intervals reflect current production (7F.04) hardware, unless otherwise noted, and
and operation in accordance with manufacturer specifications. They represent initial recommended intervals operation in accordance with manufacturer specifications. They represent initial recommended intervals in
in the absence of operating and condition experience. For factored hours and starts of the repair intervals, the absence of operating and condition experience. For factored hours and starts of the repair intervals, refer
refer to Figure 39. to Figure 39.
CI = Combustion Inspection Interval Cl = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval HGPI = Hot Gas Path Inspection Interval

Figure D-6. Estimated repair and replacement intervals Figure D-8. Estimated repair and replacement intervals

7F.03 7FB.01
Repair Interval Replace Interval (Hours) Replace Interval (Starts) Repair Interval Replace Interval (Hours) Replace Interval (Starts)
Combustion Liners Cl 2 (Cl) 2 (Cl) Combustion Liners Cl 2 (Cl) 3 (Cl)
Caps Cl 2 (Cl) 2 (Cl) Caps Cl 2 (Cl) 3 (Cl)
Transition Pieces Cl 2 (Cl) 2 (Cl) Transition Pieces Cl 2 (Cl) 3 (Cl)
Fuel Nozzles Cl 2 (Cl) 2 (Cl) Fuel Nozzles Cl 2 (Cl)(1) 3 (Cl)(1)
Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tubes Cl 1 (Cl) 1 (Cl)
Crossfire Tube CI 1 (CI) 1 (CI) Crossfire Tube CI 1 (CI) 1 (CI)
Retaining Clips Retaining Clips
End Covers CI 2 (Cl) 2 (Cl) End Covers CI 3 (Cl) 3 (Cl)
Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI)
Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 1 (HGPI) 1 (HGPI)
Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI)
Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI)
Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGP)
Stage 1 Buckets HGPI 3 (HGPI)(2) 2 (HGPI)(4) Stage 1 Buckets HGPI 1 (HGPI) 1 (HGPI)
Stage 2 Buckets HGPI 3 (HGPI)(1) 3 (HGPI)(1) Stage 2 Buckets HGPI 3 (HGPI) 3 (HGPI)
Stage 3 Buckets HGPI 3 (HGPI)(3) 3 (HGPI) Stage 3 Buckets HGPI 3 (HGPI) 3 (HGPI)
Note: Repair/replace intervals reflect current production (7F.03 DLN 2.6 24k Super B and non-AGP) hardware, Note: Repair/replace cycles reflect current production (7251(FB) DLN 2.0+ extended interval) hardware,
unless otherwise noted, and operation in accordance with manufacturer specifications. They represent initial unless otherwise noted, and operation in accordance with manufacturer specifications. They represent initial
recommended intervals in the absence of operating and condition experience. For factored hours and starts recommended intervals in the absence of operating and condition experience. For factored hours and starts
of the repair intervals, refer to Figure 39. of the repair intervals, refer to Figure 39.
Cl = Combustion Inspection Interval Cl = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval HGPI = Hot Gas Path Inspection Interval
(1) 3 (HGPI) for current design. Consult your GE service representative for replacement intervals by part (1) Blank and liquid fuel cartridges to be replaced at each CI
number.
(2) GE approved repair procedure required at first HGPI for designs without platform cooling. Figure D-9. Estimated repair and replacement intervals
(3) GE approved repair procedure at 2nd HGPI is required to meet 3 (HGPI) replacement life.
(4) 2 (HGPI) for current design with GE approved repair at first HGPI. 3 (HGPI) is possible for redesigned bucket
with platform undercut and cooling modifications.

Figure D-7. Estimated repair and replacement intervals

42
9F.03 9F.05
Repair Interval Replace Interval (Hours) Replace Interval (Starts) Repair Interval Replace Interval (Hours) Replace Interval (Starts)
Combustion Liners Cl 2 (Cl) 3 (Cl) Combustion Liners CI 4 (CI) 4 (CI)
Caps Cl 2 (Cl) 3 (Cl) Caps CI 4 (CI) 4 (CI)
Transition Pieces Cl 2 (Cl) 3 (Cl) Transition Pieces CI 4 (CI) 4 (CI)
Fuel Nozzles Cl 2 (Cl)(1) 3 (Cl)(1) Fuel Nozzles CI 2 (Cl)(1) 2 (CI)(1)
Crossfire Tubes Cl 1 (Cl) 1 (Cl) Crossfire Tubes CI 1 (Cl) 1 (Cl)
Crossfire Tube CI 1 (CI) 1 (CI) Crossfire Tube CI 1 (CI) 1 (CI)
Retaining Clips Retaining Clips
End Covers CI 2 (Cl) 3 (Cl) End Covers CI 4 (CI) 4 (CI)
Stage 1 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 1 Nozzles HGPI 1 (HGPI) 1 (HGPI)
Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI) Stage 2 Nozzles HGPI 2 (HGPI) 2 (HGPI)
Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI) Stage 3 Nozzles HGPI 3 (HGPI) 3 (HGPI)
Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 1 Shrouds HGPI 2 (HGPI) 2 (HGPI)
Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI) Stage 2 Shrouds HGPI 2 (HGPI) 2 (HGPI)
Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI) Stage 3 Shrouds HGPI 3 (HGPI) 3 (HGPI)
Stage 1 Buckets HGPI 2 (HGPI)(2) 2 (HGPI)(4) Stage 1 Buckets HGPI 1 (HGPI)(2) 1 (HGPI)(2)
Stage 2 Buckets HGPI 3 (HGPI)(5) 3 (HGPI)(3) Stage 2 Buckets HGPI 1 (HGPI)(2) 1 (HGPI)(2)
Stage 3 Buckets HGPI 3 (HGPI)(5) 3 (HGPI) Stage 3 Buckets HGPI 1 (HGPI)(2) 1 (HGPI)(2)
Note: Repair/replace intervals reflect current production (9F.03 DLN 2.6+) hardware, unless otherwise noted,
Note: Repair/replace intervals reflect current production (9F.05) hardware, unless otherwise noted, and
and operation in accordance with manufacturer specifications. They represent initial recommended intervals
operation in accordance with manufacturer specifications. They represent initial recommended intervals in
in the absence of operating and condition experience. For factored hours and starts of the repair intervals,
the absence of operating and condition experience. For factored hours and starts of the repair intervals, refer
refer to Figure 39.
to Figure 39.
Cl = Combustion Inspection Interval
CI = Combustion Inspection Interval
HGPI = Hot Gas Path Inspection Interval
HGPI = Hot Gas Path Inspection Interval
(1) Blank and liquid fuel cartridges to be replaced at each CI
(1) Blank and liquid fuel cartridges to be replaced at each CI
(2) 2 (HGPI) for current design with GE approved repair at first HGPI. 3 (HGPI) is possible for redesigned bucket
with platform undercut and cooling modifications. Figure D-11. Estimated repair and replacement intervals
(3) Recoating at 1st HGPI may be required to achieve 3 HGPI replacement life.
(4) GE approved repair procedure at 1 (HGPI) is required to meet 2 (HGPI) replacement life.
(5) GE approved repair procedure is required to meet 3 (HGPI) replacement life.

Figure D-10. Estimated repair and replacement intervals

GE Power & Water | GER-3620M (05/14) 43

E) Borescope Inspection Ports
1st Stg. LE 1st Stg. TE 2nd Stg. LE 2nd Stg. TE 3rd Stg. LE-Turbine

24.5° 9.8° 10.5° 9.73° 12°

99.5° 100.5° 100.5° 189.73° 102°
Compressor 204.5° 170.2° 160.5° 155°
15th, 16th, 17th Stage
24.5° 24.5°

Primary Inspection Access

(Normal Inspection)
24.5° 24.5°
Secondary Inspection Access
(Additional Stators and Nozzles)

Compressor
0-6th Stage

Figure E-1. Borescope inspection access locations for 6F machines

1st Stg. LE 1st Stg. TE 2nd Stg. LE 2nd Stg. TE 3rd Stg. LE-Turbine
66° 15° 151° 66° 62° 130° 64° 39°
13°

Compressor
14th, 15th, 16th Stage
25° 25°
Primary Inspection Access
(Normal Inspection)
25° 25°
Secondary Inspection Access
(Additional Stators and Nozzles)

Compressor
0-5th Stage

Figure E-2. Borescope inspection access locations for 7F and 9F machines

44
F) Turning Gear/Ratchet Running Guidelines

Turning Gear
Scenario
(or Ratchet) Duration

Following Shutdown:

Until wheelspace temperatures <150°F.(1)

Case A.1 – Normal.
Rotor classified as unbowed.
Restart anticipated for >48 hours
Minimum 24 hours.(2)

Case A.2 – Normal.

Continuously until restart. Rotor unbowed.
Restart anticipated for <48 hours

Case B – Immediate rotor stop

necessary. (Stop >20 minutes)
None. Classified as bowed.
Suspected rotating hardware damage
or unit malfunction

Before Startup:

Case C – Hot rotor,

0–1 hour(3)
<20 minutes after rotor stop

Case D – Warm rotor, >20 minutes

4 hours
& <6 hours after rotor stop

Case E.1 – Cold rotor, unbowed,

4 hours
off TG <48 hours

Case E.2 – Cold rotor, unbowed,

6 hours
off TG >48 hours

Case F – Cold rotor, bowed 8 hours(4)

During Extended Outage:

Case G – When idle 1 hour daily

No TG; 1 hour/week at full speed

Case H – Alternative
(no load).(5)

(1) Time depends on frame size and ambient environment.

(2) Cooldown cycle may be accelerated using starting device for forced cooldown. Turning gear, however,
is recommended method.
(3) 1 hour on turning gear is recommended following a trip, before restarting. For normal shutdowns, use
discretion.
(4) Follow bowed rotor startup procedure, which may be found in the unit O&M Manual.
(5) Avoids high cycling of lube oil pump during long outages.

Figure F-1. Turning gear guidelines

GE Power & Water | GER-3620M (05/14) 45

G) B/E- and F-class Gas Turbine Naming

Model Prior model Prior model Model Prior model Prior model
Class Platform Prior names Class Platform Prior names
Designation series number Designation series number

- 6101(FA) 6FA.01 6FA - 6521(B) -

MS6001(FA)
6F 6F.03 6111(FA) 6FA.03 6FA+e - 6531(B) -

- - - 6F Syngas - - 6541(B) -

- 7221(FA) 7FA.01 7FA - 6551(B) -

6B MS6001(B)
- 7231(FA) 7FA.02 7FA+ - 6561(B) -
MS7001(FA)
7F.03 7241(FA) 7FA.03 7FA+e - 6571(B) -
7F
7F.04 - 7FA.04 - 6B.03 6581(B) -

F-class - MS7001(FB) 7251(FB) 7FB.01 - - - 6B PIP

- - - 7F Syngas - B/E-class - 7111(EA) -

- 9311(FA) 9FA.01 9FA 7E - MS7001(EA) 7121(EA) -

- MS9001(FA) 9331(FA) 9FA.02 9FA+ 7E.03 - 7EA PIP

9F.03 9351(FA) 9FA.03 9FA+e - 9151(E) -

9F
- 9371(FB) 9FB.01 - - 9161(E) -

- MS9001(FB) - 9FB.02 - 9E.03 9171(E) -

9E MS9001(E)
9F.05 - 9FB.03 - 9E.03 - 9E PIP

9E.03 - 9E AGP
Figure G-1. F-class gas turbine naming
- - 9E Syngas

Figure G-2. B/E-class gas turbine naming

46
List of Figures Figure 31. Susceptibility of compressor blade materials and
coatings
Figure 1. Key factors affecting maintenance planning
Figure 32. 7E.03 heavy-duty gas turbine – disassembly inspections
Figure 2. Key technical reference documents to include in
maintenance planning Figure 33. Operating inspection data parameters

Figure 3. 7E.03 gas turbine borescope inspection access locations Figure 34. Combustion inspection – key elements

Figure 4. Borescope inspection planning Figure 35. Hot gas path inspection – key elements

Figure 5. Causes of wear – hot gas path components Figure 36. Stage 1 bucket oxidation and bucket life

Figure 6. GE bases gas turbine maintenance requirements on Figure 37. Gas turbine major inspection – key elements
independent counts of starts and hours Figure 38. First-stage nozzle repair program: natural gas fired –
Figure 7. Hot gas path maintenance interval comparisons. GE continuous dry – base load
method vs. EOH method Figure 39. Baseline recommended inspection intervals: base load –
Figure 8. Maintenance factors natural gas fuel – dry

Figure 9. GE maintenance intervals Figure 40. Combustion inspection hours-based maintenance

factors
Figure 10. Estimated effect of fuel type on maintenance
Figure 41. Combustion inspection starts-based maintenance
Figure 11. Peak fire severity factors - natural gas and light distillates factors
Figure 12. Firing temperature and load relationship – heat recovery Figure 42. Hot gas path maintenance interval: hours-based criterion
vs. simple cycle operation
Figure 43. Hot gas path maintenance interval: starts-based criterion
Figure 13. Exhaust temperature control curve – dry vs. wet control
7E.03 Figure 44. Rotor maintenance interval: hours-based criterion

Figure 14. Peaking-fast start factors Figure 45. Rotor maintenance interval: starts-based criterion

Figure 15. 7F.03 fast start factors Figure D-1. Estimated repair and replacement intervals

Figure 16. Turbine start/stop cycle – firing temperature changes Figure D-2. Estimated repair and replacement intervals

Figure 17. Second stage bucket transient temperature distribution Figure D-3. Estimated repair and replacement intervals

Figure 18. Bucket low cycle fatigue (LCF) Figure D-4. Estimated repair and replacement intervals

Figure 19. Low cycle fatigue life sensitivities – first stage bucket Figure D-5. Estimated repair and replacement intervals

Figure 20. Maintenance factor – trips from load Figure D-6. Estimated repair and replacement intervals

Figure 21. Maintenance factor – effect of start cycle maximum load Figure D-7. Estimated repair and replacement intervals
level Figure D-8. Estimated repair and replacement intervals
Figure 22. Operation-related maintenance factors Figure D-9. Estimated repair and replacement intervals
Figure 23. 7F gas turbine typical operational profile Figure D-10. Estimated repair and replacement intervals
Figure 24. Baseline for starts-based maintenance factor definition Figure D-11. Estimated repair and replacement intervals
Figure 25. DLN combustion mode effect on combustion hardware Figure E-1. Borescope inspection access locations for 6F machines
life Figure E-2. Borescope inspection access locations for 7F and 9F
Figure 26. F-class axial diffuser machines
Figure 27. E-class radial diffuser Figure F-1. Turning gear guidelines
Figure 28. Maintenance factor for overspeed operation ~constant Figure G-1. F-class gas turbine naming
TF Figure G-2. B/E-class gas turbine naming
Figure 29. Deterioration of gas turbine performance due to
compressor blade fouling
Figure 30. Long-term material property degradation in a wet
environment

GE Power & Water | GER-3620M (05/14) 47

Revision History
9/89 Original • Procedural clarifications for HGP inspection added
8/91 Rev A • Added inspections for galling/fretting in turbine dovetails to
major inspection scope
9/93 Rev B
• HGP factored starts calculation updated for application of
3/95 Rev C
trip factors
• Nozzle Clearances section removed
• Turning gear maintenance factor removed for F-class hours-
• Steam/Water Injection section added based rotor life
• Cyclic Effects section added • Removed reference to turning gear effects on cyclic
5/96 Rev D customers’ rotor lives

• Estimated Repair and Replacement Cycles added for F/FA • HGP factored starts example added
• F-class borescope inspection access locations added
11/96 Rev E
• Various HGP parts replacement cycles updated and
11/98 Rev F
additional 6B table added
• Rotor Parts section added
• Revision History added
• Estimated Repair and Replace Cycles added for FA+E
11/09 Rev L
• Starts and hours-based rotor maintenance interval
• Updated text throughout
equations added
• Casing section added
9/00 Rev G
• Exhaust Diffuser section added
11/02 Rev H • Added new Fig. 26: F-class axial diffuser
• Estimated Repair and Replace Cycles updated and moved to • Added new Fig. 27: E-class radial diffuser
Appendix D
• Revised Fig. 3, 5, 7, 8, 11, 19, 20, 23, 35, 37, 38, 40, 41, 42, 43,
• Combustion Parts section added 44, E-1, and E-2
• Inlet Fogging section added • Appendix D – updated repair and replacement cycles
1/03 Rev J • Added PG6111 (FA) Estimated repair and replacement cycles
• Off Frequency Operation section added • Added PG9371 (FB) Estimated repair and replacement cycles

10/04 Rev K 10/10 Correction L.1

• GE design intent and predication upon proper components • Corrected Fig. D-4, D-5, and D-11 combustion hardware
and use added repair and replacement cycles
• Added recommendation for coalescing filters installation 4/14 Rev M
upstream of gas heaters
• Updated text throughout
• Added recommendations for shutdown on gas fuel, dual fuel
• Added Fig. 14, 15, 25
transfers, and FSDS maintenance
• Revised Fig. 8, 10, 12, 22, 29, 34, 35, 37, 39, 41, 42, 43, 44, 45
• Trip from peak load maintenance factor added
• Updated Appendix A
• Lube Oil Cleanliness section added
• Updated Appendix D
• Inlet Fogging section updated to Moisture Intake
• Added 7F.04 Estimated repair and replacement intervals
• Best practices for turning gear operation added
• Added Appendix G
• Rapid Cool-down section added

48
GE Power & Water | GER-3620M (05/14) 49
50
 GTD-222, GTD-241, GTD-450, GECC-1, and Extendor are trademarks of the General Electric Company.

©2014, General Electric Company. All rights reserved.

4 GER-3620M (05/14)
Tab 26
DWG Number 399A4822 Rev B Released 7/23/2013 Page 1 of 67
SIZE DWG NO SH REV
A 399A4822 1 B
REVISION HISTORY
REV ZONE DESCRIPTION DATE APPROVED
YYYY-MM-DD

A DEVICE SUMMARY SYSTEM 4027 2013-02-06 DRAWN

UPDATED PER ISS-0034683. SV
REFER ISSUE NOTES IN DEVICE
ENGINEER
SUMMARY FOR DETAILS OF
MLL
CHANGE. ECO0090698 SELVAM
VELUSAMY.
B AS PER ISS0050596 RM THE 2013-07-22 DRAWN
FOLLOWING DEVICES WERE 502209130
ADDED:
ENGINEER
20TW-7,96WW-4,VA16-4.
502036044
AS PER ISS0050596 RM THE
FOLLOWING DEVICE IS
MODIFIED:
PI-WW-13

THIS DOCUMENT SHALL BE REVISED

IN ITS ENTIRETY. ALL SHEETS OF
THIS DOCUMENT ARE THE SAME
REVISION LEVEL AS INDICATED.

REVISION DESCRIPTION IS FULLY

STATED ON FIRST SHEET OF
DOCUMENT
© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

DRAWING TYPE
SIGNATURES
DRAWN BALLA, SANKAR GE Energy
DRAWN DATE 2012-12-11
GENERAL ELECTRIC COMPANY
CHECKED LUBBERT, MARK
CHECKED DATE
ENGRG BALLA, SANKAR
Device Summary
ENGRG DATE
FIRST MADE FOR ML: DM:720103 CC:0414
APPLIED PRACTICES ADDITIONAL APPROVALS
SIZE CAGE CODE DWG NO
SEE PLM FOR APPROVAL
INFORMATION A 399A4822
SIM TO: SHEET 1 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 2 of 67

A
SIZE DWG NO SH REV
399A4822 2 B
System Title
0415 CONTROL DEVICES -TURBINE
0416 LUBE OIL SYSTEM
0417 COOL & SEAL AIR SYSTEM
0419 CONTROL AIR
0420 COOLING WATER SYSTEM
0422 GAS FUEL SYSTEM
0426 FIRE PROTECTION SYSTEM
0432 INLET AIR HEATING
0434 HYDRAULIC SUPPLY SYSTEM
0436 HEAT & VENT SYSTEM
0440 LOAD EQUIPMENT
0442 TURBINE & COMPRESSOR WASH
0471 INLET AND EXHAUST
0474 HAZARDOUS GAS DETECTION
0477 FUEL PURGE
0492 PERFORMANCE MONITOR
4027 H2 ACCESSORIES (Ref. G2FA)
4035 FUEL GAS CHROMATOGRAPGH

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 2 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 3 of 67

A
SIZE DWG NO SH REV
399A4822 3 B
NOTES

Rev "B"

Device System Operation

20TW-7 0442 Added

96WW-4 0442 Added
VA16-4 0442 Added
PI-WW-13 0442 Modified

Sivasubramaniam
22JUL13
-----------------------------------------
Rev "A"

Device System Operation

PSL-2950 4027 Deleted

Selvam Velusamy
06FEB13

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 3 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 4 of 67

A
SIZE DWG NO SH REV
399A4822 4 B
SWITCH SETTINGS
Contact Condition Additional Contacts
NO- Normally open CEC Additional contact:
- Normally closed
Electrically common
NC- Normally closed CES Additional contact:
- Normally closed
Electrically separate
()- Parenthesis indicates sets of OEC Additional contact:
contacts - Normally open
Electrically common
OES Additional contact:
- Normally open
Electrically separate

Example: NORM=(2) NO-CEC

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 4 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 5 of 67

A
SIZE DWG NO SH REV
399A4822 5 B

Device System Settings

20-TQ2-2 0417 SOLENOID VALVE
DE-ENERGIZED:3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC;
DE-ENERGIZED TO TRIP OPEN VA7-2
20-TQ2-4 0417 SOLENOID VALVE
DE-ENERGIZED : 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED : 1 TO 2 OPEN; 3 PLUGGED
125 VDC;
DE-ENERGIZED TO TRIP CLOSED VA7-3
20AP-1 0419 APU SHUTOFF VALVE.
DE-ENERGIZED: 1 TO 2 CLOSED
ENERGIZED: 1 TO 2 OPEN
230 VAC; 50 HZ; SINGLE PHASE
PROTECTS DESSICANT FROM OVER TEMPERATURE. CONTROL SIGNAL NAME
IS L20AP1, APU TROUBLE RELAY (SHUT-OFF VALVE CLOSE RELAY). WIRE TO
MKV / MARKVI.
20CB-1 0417 COMPRESSOR BLEED SOL VALVE
NORM=B TO C OPEN; A CLOSED
20CB-2 0417 COMPRESSOR BLEED SOL VALVE
NORM B TO C OPEN; A CLOSED
20CM-1 0417 CASE TEMP. MANAGEMENT FLOW CONTROL DAMPER
FAILED POSITION = CLOSED
20FGC-1 0422 FUEL GAS CONTROL VALVE SOLENOID VALVE
DE-ENERGIZED: 1 TO 2 OPEN
ENERGIZED: 1 TO 2 CLOSED
125 VDC;
20FGC-2 0422 FUEL GAS CONTROL VALVE SOLENOID VALVE
DE-ENERGIZED: 1 TO 2 OPEN
ENERGIZED: 1 TO 2 CLOSED
125 VDC;
20FGC-3 0422 FUEL GAS CONTROL VALVE SOLENOID VALVE
DE-ENERGIZED: 1 TO 2 OPEN
ENERGIZED: 1 TO 2 CLOSED
125 VDC;
20FGS-1 0422 FUEL GAS STOP VALVE SOLENOID VALVE
DE-ENERGIZED: 1 TO 2 OPEN
ENERGIZED: 1 TO 2 CLOSED
125 VDC;
20PG-1 0477 GAS FUEL SYSTEM PURGE SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 5 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 6 of 67

A
SIZE DWG NO SH REV
399A4822 6 B

Device System Settings

20PG-2 0477 GAS FUEL SYSTEM PURGE SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC;
20PG-5 0477 GAS FUEL SYSTEM PURGE SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC;
PART OF VA13-5
20PG-6 0477 GAS FUEL SYSTEM PURGE AIR SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC;
PART OF VA13-6
20QB-1 0434 LIFT OIL SUPPLY ISOLATION VALVE
DE-ENERGIZED: 1 TO 2 CLOSED
ENERGIZED: 1 TO 2 OPEN
230 VAC; 50 HZ;
1 PH
20TH-1 0432 INLET HEATING CONTROL VALVE TRIP SOLENOID VALVE
125 VDC;
DE-ENERGIZE TO TRIP VA20-1
ENERGIZE TO OPERATE VA20-1
AREA CLASSIFICATION : NON-RATED
PROTECTION METHOD : D-FLAMEPROOF
20TV-1 0434 TURBINE COMPRESSOR IGV SOLENOID VALVE
125 VDC;
20TW-4 0442 OFF-LINE COMPRESSOR WASH WATER INJ SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC; 20.60 W; 0.1600 A;
PART OF VA16-1
20TW-6 0442 ON-LINE COMPRESSOR WASH WATER INJ SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC; 20.60 W; 0.1600 A;
PART OF VA16-3
20TW-7 0442 GFC WATER INJ SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC; 20.60 W; 0.1600 A;
PART OF VA16-4

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 6 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 7 of 67

A
SIZE DWG NO SH REV
399A4822 7 B

Device System Settings

20VG-1 0422 FUEL GAS VENT SOLENOID VALVE TEST
DE-ENERGIZED: 1 TO 3 OPEN; 2 PLUGGED
ENERGIZED: 2 TO 1 OPEN; 3 PLUGGED
125 VDC;
20VG-2 0477 FUEL GAS VENT SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC; 10.60 W; 0.0800 A;
PART OF VA13-8
20VG-4 0477 GAS FUEL VENT SOLENOID VALVE
DE-ENERGIZED: 3 TO 1 OPEN; 2 PLUGGED
ENERGIZED: 1 TO 2 OPEN; 3 PLUGGED
125 VDC; 10.60 W; 0.0800 A;
PART OF VA13-13
20VG-8 0422 FUEL GAS VENT SOLENOID VALVE
DE-ENERGIZED: 1 TO 3 OPEN; 2 PLUGGED
ENERGIZED: 2 TO 1 OPEN; 3 PLUGGED
125 VDC;
20VS4-1 0422 FUEL GAS AUXILIARY STOP VALVE
20VS4-4 0422 FUEL GAS SAFETY SHUTOFF VALVE-SOLENOID VALVE
20WDET 0442 SOLENOID, 2 WAY VALVE TO RECIRCULATE WATER BACK TO TANK.
230 VAC; 50 HZ;
1 PH;
DE-ENERGIZED: 1 TO 2 CLOSED
ENERGIZED: 1 TO 2 OPEN
CONTROL SIGNAL NAME IS L20WDET. WIRE TO MK V / MK VI. MK V / MK VI
OUTPUT SIGNAL IS DRY CONTACT.
23BL-1 0436 FAN MOTOR HEATER FOR 88BL-1
60.00 W; 230 VAC; 1 PH; 50 HZ;
23BL-2 0436 FAN MOTOR HEATER FOR 88BL-2
60.00 W; 230 VAC; 1 PH; 50 HZ;
23BN-1 0417 SPACE HEATER
100.0 W; 230 VAC; 1 PH; 50 HZ;
MAX WATTAGE
FOR MOTOR 88BN-1
23BN-2 0417 SPACE HEATER
100.0 W; 230 VAC; 1 PH; 50 HZ;
MAX WATTAGE
FOR MOTOR 88BN-2
23BT-1 0436 HEATER-TURBINE COMPT FAN MOTOR
200.0 W; 230 VAC; 1 PH; 50 HZ;
HAZARDOUS ZONE: ZONE 2
PROTECTION METHOD: `D` - FLAMEPROOF

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 7 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 8 of 67

A
SIZE DWG NO SH REV
399A4822 8 B

Device System Settings

23BT-2 0436 HEATER-TURBINE COMPT FAN MOTOR
200.0 W; 230 VAC; 1 PH; 50 HZ;
HAZARDOUS ZONE: ZONE 2
PROTECTION METHOD: `D` - FLAMEPROOF
23CM-1 0417 CASE TEMP. MANAGEMENT BLOWER MOTOR SPACE HEATER
120.0 W; 230 VAC; 1 PH; 50 HZ;
FOR MOTOR 88CM-1
23HG-1 0440 SPACE HEATER-GENERATOR
2.250 KW; 400 VAC; 3 PH; 50 HZ;
23HG-2 0440 SPACE HEATER-GENERATOR
2.250 KW; 400 VAC; 3 PH; 50 HZ;
23HL-1 0436 SPACE HEATER-LUBE OIL SKID
20.00 KW; 400 VAC; 3 PH; 50 HZ;
HEATING FOR FREEZE PROTECTION
23HL-3 0436 SPACE HEATER-ACCESSORY COMPT, LUBE OIL REGION
3.600 KW; 400 VAC; 1 PH; 50 HZ;
USED FOR HUMIDITY CONTROL
23HQ-1 0434 HEATER-HYDRAULIC OIL PUMP MOTOR
60.00 W; 230 VAC; 1 PH; 50 HZ;
23HQ-2 0434 SPACE HEATER-HYDRAULIC PUMP MOTOR
60.00 W; 230 VAC; 1 PH; 50 HZ;
23HT-1A 0436 SPACE HEATER-TURBINE COMPARTMENT
30.00 KW; 400 VAC; 3 PH; 50 HZ;
HEATING FOR FREEZE PROTECTION
23HT-1B 0436 SPACE HEATER-TURBINE COMPARTMENT
30.00 KW; 400 VAC; 3 PH; 50 HZ;
HEATING FOR FREEZE PROTECTION
23HT-3A 0436 SPACE HEATER-TURBINE COMPARTMENT
3.600 KW; 400 VAC; 1 PH; 50 HZ;
HEATING FOR HUMIDITY CONTROL
23HT-3B 0436 SPACE HEATER-TURBINE COMPARTMENT
3.600 KW; 400 VAC; 1 PH; 50 HZ;
HEATING FOR HUMIDITY CONTROL
23IC-1 0471 MOTOR HEATER FOR DEVICE 88IC-1
35.00 W; 230/480 VAC; 1 PH; 50 HZ;
23KE-1 0440 HEATER-GENERATOR COLLECTOR ENCLOSURE
150.0 W; 230 VAC; 1 PH; 50 HZ;
23QA-1 0416 HEATER-AUX LUBE OIL PUMP MOTOR
100.0 W; 230 VAC; 1 PH; 50 HZ;
23QA-2 0416 SPACE HEATER-AUX LUBE OIL PUMP MOTOR
100.0 W; 230 VAC; 1 PH; 50 HZ;
23QS-1 0416 HEATER-SEAL OIL PUMP MOTOR
60.00 W; 230 VAC; 1 PH; 50 HZ;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 8 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 9 of 67

A
SIZE DWG NO SH REV
399A4822 9 B

Device System Settings

23QT-1 0416 IMMERSION HEATER-LUBE OIL TANK
12.00 KW; 400 VAC; 3 PH; 50 HZ;
23QT-2 0416 IMMERSION HEATER-LUBE OIL TANK
12.00 KW; 400 VAC; 3 PH; 50 HZ;
23QT-3 0416 IMMERSION HEATER-LUBE OIL TANK
12.00 KW; 400 VAC; 3 PH; 50 HZ;
23QV-2A 0416 SPACE HEATER-FOR 88QV-1A
60.00 W; 230 VAC; 1 PH; 50 HZ;
23QV-2B 0416 SPACE HEATER-FOR 88QV-1B
60.00 W; 230 VAC; 1 PH; 50 HZ;
23TG-1 0416 TURNING GEAR MOTOR HEATER
75.00 W; 230 VAC; 1 PH; 50 HZ;
23TK-1 0417 TURBINE SHELL & EXHAUST FRAME BLOWER MOTOR HEATER
225.0 W; 230 VAC; 1 PH; 50 HZ;
MAX WATTAGE
FOR MOTOR 88TK-1
23TK-2 0417 TURBINE SHELL & EXHAUST FRAME BLOWER MOTOR HEATER
225.0 W; 230 VAC; 1 PH; 50 HZ;
MAX WATTAGE
FOR MOTOR 88TK-2
23TW-1 0442 HEATER-WATER WASH PUMP MOTOR
60.00 W; 230 VAC; 1 PH; 50 HZ;
(PART OF 88TW-1)
23VG-1 0436 HEATER-VENTILATION FAN MOTOR (LOAD COMPT)
60.00 W; 230 VAC; 1 PH; 50 HZ;
23VG-2 0436 HEATER-VENTILATION FAN MOTOR (LOAD COMPT)
60.00 W; 230 VAC; 1 PH; 50 HZ;
23VS-1 0436 SPACE HEATER-VALVE COMPARTMENT
20.00 KW; 400 VAC; 3 PH; 50 HZ;
HEATING FOR FREEZE PROTECTION
23VS-3 0436 SPACE HEATER-ACCESSORY COMPT, GAS FUEL MOD REGION
3.600 KW; 400 VAC; 1 PH; 50 HZ;
USED FOR HUMIDITY CONTROL
23WK-1 0442 IMMERSION HEATER WATER WASH
45.00 KW; 400 VAC; 3 PH; 50 HZ;
23WK-2 0442 IMMERSION HEATER WATER WASH
45.00 KW; 400 VAC; 3 PH; 50 HZ;
23WS-1 0442 WATER WASH SKID SPACE HEATER
10.00 KW; 400 VAC; 3 PH; 50 HZ;
26TG-1 0416 THERMOSTAT, TURNING GEAR MOTOR WINDING

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 9 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 10 of 67

A
SIZE DWG NO SH REV
399A4822 10 B

Device System Settings

26TW-4 0442 -5 TO 50 MV, TEMPERATURE ELEMENT FOR TANK TEMPERATURE.
TYPE J THERMOCOUPLE
1 ELEMENT;
INCREASING: 180.0 +/- 5.0 F OR 82.22 +/- 2.778 C
DECREASING: 52.0 +/- 2.0 F OR 11.11 +/- 1.111 C
THIRD SET-POINT 75.0 +/- 2 F INCREASING
26VW-3 0442 TEMP. ELEMENT FOR COMPT. SPACE HEATER AND VENT FAN.
TYPE J THERMOCOUPLE
1 ELEMENT;
OPERATE VENT FAN AT 95 DEGREES F INCREASING.
OPERATE SPACE HEATER AT 65 DEGREES F DECREASING.
ALARM AT 43 DEGREES F DECREASING.
ALARM AT 130 DEGREES F INCREASING.
27AD-1 0419 APU LOSS OF POWER ALARM
CONTROL SIGNAL NAME IS L27AD1. WIRE TO MK V / MK VI.
27TF-1 0471 GT AIR FILTER GENERAL ALARM DISPATCHING

1 PH, 2A RESISTIVE, 125VDC, 0.2A INDUCTIVE

NORM=(1) NO;
27WD-1 0442 WATER WASH SKID LOSS OF POWER ALARM RELAY
WIRE TO MKV / MK VI
28FD-15 0415 FLAME DETECTOR COMBUSTION CHAMBER #15
28FD-16 0415 FLAME DETECTOR COMBUSTION CHAMBER #16
28FD-17 0415 FLAME DETECTOR COMBUSTION CHAMBER #17
28FD-18 0415 FLAME DETECTOR COMBUSTION CHAMBER #18
2FP-1A 0426 FIRE PROTECTION-INITIAL DISCHARGE TIMER (ZONE 1)
(ZONE 1)
INITIAL DISCHARGE
2FP-1AE 0426 FIRE PROTECTION-EXTENDED DISCHARGE TIMER (ZONE 1)
(ZONE 1)
EXTENDED DISCHARGE
2FP-2A 0426 FIRE PROTECTION-INITIAL DISCHARGE TIMER (ZONE 2)
(ZONE 2)
INITIAL DISCHARGE
2FP-2AE 0426 FIRE PROTECTION-EXTENDED DISCHARGE TIMER (ZONE 2)
(ZONE 2)
EXTENDED DISCHARGE
2FP-3A 0426 FIRE PROTECTION-INITIAL DISCHARGE TIMER (ZONE 3)
(ZONE 3)
INITIAL DISCHARGE

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 10 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 11 of 67

A
SIZE DWG NO SH REV
399A4822 11 B

Device System Settings

2FP-3AE 0426 FIRE PROTECTION-EXTENDED DISCHARGE TIMER (ZONE 3)
(ZONE 3)
EXTENDED DISCHARGE
30FP-10A 0426 FIRE PROTECTION TRIP CONTACT
ZONE 1 PRE-DISCHARGE CONTACT
NORM=(1) NO-CEC;
CONTACT IS AVAILABLE FOR CUSTOMER USE. CLOSES UPON START OF PRE-
DISCHARGE TIMER. CONTACT RATED FOR 5A@24VDC OR 120VAC.
30FP-1A 0426 TROUBLE ANNUNCIATOR CONTACT
NORM=(1) NC; 125VDC CONTACT;
CONTACT WIRED TO TCP AND OPENS TO INDICATE A FAULT IN THE FIRE
PROTECTION SYSTEM
30FP-1B 0426 SUPERVISORY ANNUNCIATOR CONTACT
NORM=(1) NC; 125VDC CONTACT;
CONTACT WIRED TO TCP AND OPENS TO INDICATE THE FIRE PROTECTION
FLUID HAS BEEN ISOLATED FROM THE PROTECTED SPACES
30FP-20A 0426 FIRE PROTECTION TRIP CONTACT (ZONE 2)
ZONE 2 PRE-DISCHARGE CONTACT
NORM=(1) NO-CEC;
CONTACT IS AVAILABLE FOR CUSTOMER USE. CLOSES UPON START OF PRE-
DISCHARGE TIMER. CONTACT RATED FOR 5A@24VDC OR 120VAC.
30FP-2A 0426 TROUBLE ANNUNCIATOR CONTACT
NORM=(1) NC;
CUSTOMER CONTACT. OPENS TO INDICATE A TROUBLE CONDITION WITH THE
FP SYSTEM. CONTACT RATED FOR 5A@24VDC OR 120VAC
30FP-30A 0426 FIRE PROTECTION TRIP CONTACT (ZONE 3)
ZONE 3 PRE-DISCHARGE CONTACT
NORM=(1) NO-CEC;
CONTACT IS AVAILABLE FOR CUSTOMER USE. CLOSES UPON START OF PRE-
DISCHARGE TIMER. CONTACT RATED FOR 5A@24VDC OR 120VAC.
30FP-3A 0426 SUPERVISORY ANNUNCIATOR CONTACT
NORM=(1) NC;
CUSTOMER CONTACT. OPENS TO INDICATE A SUPERVISORY FAULT
CONDITION WITH THE FP SYSTEM. CONTACT RATED FOR 5A@24VDC OR
120VAC
30GCX-1 4035 FG CHROMATOGRAPH - GC A- TROUBLE ALARM
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
30GCX-2 4035 FG CHROMATOGRAPH - GC B - TROUBLE ALARM

SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315

30GCX-3 4035 FG CHROMATOGRAPH - GC A - CALIBRATION GAS ERROR ALARM
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
30GCX-4 4035 FG CHROMATOGRAPH - GC B - CALIBRATION GAS ERROR ALARM
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 11 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 12 of 67

A
SIZE DWG NO SH REV
399A4822 12 B

Device System Settings

30SG-1 0415 DIAGNOSTIC IGNITION EXCITER SWITCH
NORM=NO; CLOSE ON EXCITER FAILURE;
33-TQ2-2 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-2 OPEN
33-TQ2-3 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-2 CLOSED
33-TQ2-4 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-3 OPEN
33-TQ2-5A 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-3 CLOSED
33-TQ2-5B 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-3 CLOSED
33-TQ2-5C 0417 LIMIT SWITCH
LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACTS CLOSE TO INDICATE VALVE VA7-3 CLOSED
33CB-1 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-1 VALVE IS OPEN
33CB-2 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-2 VALVE IS OPEN
33CB-3 0417 COMP BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-3 VALVE IS OPEN
33CB-4 0417 COMP BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-4 VALVE IS OPEN
33CB-5 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-1 VALVE IS CLOSED
33CB-6 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-2 VALVE IS CLOSED

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 12 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 13 of 67

A
SIZE DWG NO SH REV
399A4822 13 B

Device System Settings

33CB-7 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-3 VALVE IS CLOSED
33CB-8 0417 COMPRESSOR BLEED VALVE LIMIT SWITCH
NORM=(1) NO;
SWITCH IS CLOSED WHEN VA2-4 VALVE IS CLOSED
33FP-31 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33FP-31E 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33FP-32 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33FP-32E 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33FP-33 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33FP-33E 0426 FIRE PROTECTION-LOCK-OUT VALVE/LIMIT SWITCH
NORM=(2) NC-OEC;
SUPERVISES DISCHARGE PIPING ISOLATION VALVE. SWITCH IS CLOSED WHEN
VALVE IS OPEN
33PG-1 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES;
33PG-10 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES;
CLOSED WITH VALVE OPEN
PART OF VA13-5
33PG-11 0477 FUEL GAS PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES;
CLOSED WITH VALVE CLOSED
PART OF VA13-6
33PG-12 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES;
CLOSED WITH VALVE OPEN
PART OF VA13-6

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 13 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 14 of 67

A
SIZE DWG NO SH REV
399A4822 14 B

Device System Settings

33PG-15 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE 55% OPEN;
PART OF VA13-2
33PG-16 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE CLOSED;
SPARE
PART OF VA13-2
33PG-2 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE OPEN;
33PG-3 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE CLOSED;
33PG-4 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE 17% OPEN;
PART OF VA13-2
33PG-9 0477 FUEL GAS SYSTEM PURGE VALVE LIMIT SWITCH
NORM=(2) NO-CES; CLOSED WITH VALVE CLOSED;
PART OF VA13-5
33TH-3 0432 INLET HEATING ISOLATION VALVE LIMIT SWITCH
NORM=(1) NO-CEC;
CONTACT CLOSED WITH VM15-1 FULL OPEN
AREA CLASSIFICATION : NON-RATED
PROTECTION METHOD : D-FLAMEPROOF
33VG-4 0422 GAS FUEL VENT VALVE-LIMIT SWITCH
NORM=(1) NO-CEC;
SWITCH CLOSES WHEN VALVE CLOSES
33VG-8 0422 GAS FUEL VENT VALVE-LIMIT SWITCH
NORM=(1) NO-CEC;
SWITCH CLOSES WHEN VALVE OPENS
33VG-9 0422 GAS FUEL VENT VALVE-LIMIT SWITCH
NORM=(1) NO-CEC;
SWITCH CLOSES WHEN VALVE CLOSES
33VS4-1 0422 FUEL GAS STOP VALVE-LIMIT SWITCH
SWITCH CLOSES WHEN VALVE OPENS
NORM=(1) NO-CEC;
33VS4-2 0422 FUEL GAS STOP VALVE-LIMIT SWITCH
SWITCH CLOSES WHEN VALVE CLOSES
NORM=(1) NO-CEC;
33VS4-4 0422 FUEL GAS STOP VALVE-LIMIT SWITCH
SWITCH CLOSES WHEN VALVE OPENS
NORM=(1) NO-CEC;
33VS4-5 0422 FUEL GAS STOP VALVE-LIMIT SWITCH
SWITCH CLOSES WHEN VALVE CLOSES
NORM=(1) NO-CEC;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 14 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 15 of 67

A
SIZE DWG NO SH REV
399A4822 15 B

Device System Settings

34AD-1 0419 AIR DRYER
100.0 W; 230 VAC; 1 PH; 50 HZ;
HEATLESS DRYER
34TF-1 0471 TURBINE INLET AIR FILTER-SELF CLEANING SEQUENCER
1 PH
230 VAC; 50 HZ;
39V-1A 0415 VIBRATION SENSOR TURBINE
OUTPUT AT 1``/SEC = 150.0 MV
39V-1B 0415 VIBRATION SENSOR TURBINE
OUTPUT AT 1``/SEC = 150.0 MV
39V-2A 0415 VIBRATION SENSOR TURBINE
OUTPUT AT 1``/SEC = 150.0 MV
39V-2B 0415 VIBRATION SENSOR TURBINE
OUTPUT AT 1``/SEC = 150.0 MV
39V-4A 0440 VIBRATION SENSOR GENERATOR
OUTPUT AT 1``/SEC = 150.0 MV
LOCATED ON TURBINE END BEARING CAP
39V-4B 0440 VIBRATION SENSOR GENERATOR
OUTPUT AT 1``/SEC = 150.0 MV
LOCATED ON TURBINE END BEARING CAP
39V-5A 0440 VIBRATION SENSOR GENERATOR
OUTPUT AT 1``/SEC = 150.0 MV
LOCATED ON COLLECTOR END BEARING CAP
39VS-101 0440 VIBRATION SENSOR (NON-CONT) GEN COLLECTOR END
BENTLEY NEVADA, 3300 SERIES
PROXIMITY PROBE FOR GENERATOR SHAFT
RANGE:200 MV PER MILLIINCH
ALARM @ 0.006``
39VS-102 0440 VIBRATION SENSOR (NON-CONT) GEN COLLECTOR END
BENTLEY NEVADA, 3300 SERIES
PROXIMITY PROBE FOR GENERATOR SHAFT
RANGE:200 MV PER MILLIINCH
ALARM @ 0.006``
39VS-11 0415 VIBRATION SENSOR (NON-CONTACTING)
OUTPUT AT 1 MIL = 200.0 MV
39VS-12 0415 VIBRATION SENSOR (NON-CONTACTING)
OUTPUT AT 1 MIL = 200.0 MV
39VS-21 0415 VIBRATION SENSOR (NON-CONTACTING)
OUTPUT AT 1 MIL = 200.0 MV
39VS-22 0415 VIBRATION SENSOR (NON-CONTACTING)
OUTPUT AT 1 MIL = 200.0 MV

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 15 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 16 of 67

A
SIZE DWG NO SH REV
399A4822 16 B

Device System Settings

39VS-91 0440 VIBRATION SENSOR (NON-CONT) GEN COUPLING END
BENTLEY NEVADA, 3300 SERIES
PROXIMITY PROBE FOR GENERATOR SHAFT
RANGE:200 MV PER MILLIINCH
ALARM @ 0.006``
39VS-92 0440 VIBRATION SENSOR (NON-CONT) GEN COUPLING END
BENTLEY NEVADA, 3300 SERIES
PROXIMITY PROBE FOR GENERATOR SHAFT
RANGE:200 MV PER MILLIINCH
ALARM @ 0.006``
43MRA-1C 0426 MANUAL DISCHARGE SWITCH (ACCESSORY COMPT)
LOCATED OUTSIDE NEXT TO ACCESSORY COMPARTMENT DOOR (ZONE 1)
43MRA-3A 0426 MANUAL DISCHARGE SWITCH (ACCESSORY MODULE)
LOCATED OUTSIDE NEXT TO ACCESSORY COMPARTMENT DOOR (ZONE 3)
43MRA-3B 0426 MANUAL DISCHARGE SWITCH (ACCESSORY MODULE)
LOCATED OUTSIDE NEXT TO ACCESSORY COMPARTMENT DOOR (ZONE 3)
43MRFP-1A 0426 FIRE PROTECTION-MANUAL DISCHARGE SWITCH (ZONE 1)
NORM=(2) NC-OEC;
LOCATED ON ELECTRICAL CONTROL CABINET DOOR ON CO2 SKID. SWITCH
HELD OPEN WITH PIN.
43MRFP-2A 0426 FIRE PROTECTION-MANUAL DISCHARGE SWITCH (ZONE 2)
NORM=(2) NC-OEC;
LOCATED ON ELECTRICAL CONTROL CABINET DOOR ON CO2 SKID. SWITCH
HELD OPEN WITH PIN.
43MRFP-3A 0426 FIRE PROTECTION-MANUAL DISCHARGE SWITCH (ZONE 3)
NORM=(2) NC-OEC;
LOCATED ON ELECTRICAL CONTROL CABINET DOOR ON CO2 SKID. SWITCH
HELD OPEN WITH PIN.
43MRT-1A 0426 MANUAL DISCHARGE SWITCH (TURBINE COMPT)
(ZONE1)
LOCATED ON COMPARTMENT WALL OUTSIDE NEXT TO DOOR
43MRT-1B 0426 MANUAL DISCHARGE SWITCH (TURBINE COMPT)
(ZONE1)
LOCATED ON COMPARTMENT WALL OUTSIDE NEXT TO DOOR
43WK-1 0442 WATER TEMP SETPOINT SWITCH (HOT-COLD)
43WK-2 0442 OPERATION SETPOINT SWITCH (AUTO-MANUAL)
45FA-30A 0426 FIRE DETECTOR-LUBE/HYDRAULIC COMPARTMENT
INCREASING: 325.0 F OR 162.8 C
NORM=(1) NO-SPST;
(LUBE/HYDRAULIC COMP.-ACCESS.MOD-ZONE 3)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 16 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 17 of 67

A
SIZE DWG NO SH REV
399A4822 17 B

Device System Settings

45FA-30B 0426 FIRE DETECTOR-LUBE/HYDRAULIC COMPARTMENT
INCREASING: 325.0 F OR 162.8 C
NORM=(1) NO-SPST;
(LUBE/HYDRAULIC COMP.-ACCESS.MOD-ZONE 3)
45FA-31A 0426 FIRE DETECTOR-LUBE/HYDRAULIC COMPARTMENT
INCREASING: 325.0 F OR 162.8 C
NORM=(1) NO-SPST;
(LUBE/HYDRAULIC COMP.-ACCESS.MOD-ZONE 3)
45FA-31B 0426 FIRE DETECTOR-LUBE/HYDRAULIC COMPARTMENT
INCREASING: 325.0 F OR 162.8 C
NORM=(1) NO-SPST;
(LUBE/HYDRAULIC COMP.-ACCESS.MOD-ZONE 3)
45FA-6A 0426 FIRE DETECTOR-FUEL GAS COMPARTMENT
INCREASING: 425.0 F OR 218.3 C
NORM=(1) NO-SPST;
FUEL GAS COMP.-ACCESS.MODULE (ZONE 1)
45FA-6B 0426 FIRE DETECTOR-FUEL GAS COMPARTMENT
INCREASING: 425.0 F OR 218.3 C
NORM=(1) NO-SPST;
FUEL GAS COMP.-ACCESS.MODULE (ZONE 1)
45FA-7A 0426 FIRE DETECTOR-FUEL GAS COMPARTMENT
INCREASING: 425.0 F OR 218.3 C
NORM=(1) NO-SPST;
FUEL GAS COMP.-ACCESS.MODULE (ZONE 1)
45FA-7B 0426 FIRE DETECTOR-FUEL GAS COMPARTMENT
INCREASING: 425.0 F OR 218.3 C
NORM=(1) NO-SPST;
FUEL GAS COMP.-ACCESS.MODULE (ZONE 1)
45FT-1A 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45FT-1B 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45FT-20A 0426 FIRE DETECTOR-#2 BEARING AREA (ZONE 2)
INCREASING: 725.0 F OR 385.0 C
NORM=(1) NO-SPST;
#2 BEARING TUNNEL - ZONE 2
45FT-20B 0426 FIRE DETECTOR-#2 BEARING AREA (ZONE 2)
INCREASING: 725.0 F OR 385.0 C
NORM=(1) NO-SPST;
#2 BEARING TUNNEL - ZONE 2

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 17 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 18 of 67

A
SIZE DWG NO SH REV
399A4822 18 B

Device System Settings

45FT-21A 0426 FIRE DETECTOR-#2 BEARING AREA (ZONE 2)
INCREASING: 725.0 F OR 385.0 C
NORM=(1) NO-SPST;
#2 BEARING TUNNEL - ZONE 2
45FT-21B 0426 FIRE DETECTOR-#2 BEARING AREA (ZONE 2)
INCREASING: 725.0 F OR 385.0 C
NORM=(1) NO-SPST;
#2 BEARING TUNNEL - ZONE 2
45FT-2A 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45FT-2B 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45FT-3A 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45FT-3B 0426 FIRE DETECTOR-TURBINE COMPARTMENT
INCREASING: 600.0 F OR 315.6 C
NORM=(1) NO-SPST;
TURBINE COMPARTMENT ZONE 1
45HA-IR-7 0474 IR COMBUSTIBLE GAS DETECTOR
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR ACCESSORY MODULE - LOCAL
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HA-IR-9A 0474 IR COMBUSTIBLE GAS DETECTOR - ACCESSORY COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR ACCESSORY MODULE - DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HA-IR-9B 0474 IR COMBUSTIBLE GAS DETECTOR - ACCESSORY COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR ACCESSORY MODULE - DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 18 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 19 of 67

A
SIZE DWG NO SH REV
399A4822 19 B

Device System Settings

45HA-IR-9C 0474 IR COMBUSTIBLE GAS DETECTOR - ACCESSORY COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR ACCESSORY MODULE - DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HGT-1 0474 HAZARDOUS ATM DETECTOR-GEN TERMINAL ENCLOSURE
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR - GTE LOCAL SENSOR
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3 MS
45HGT-2 0474 HAZARDOUS ATM DETECTOR-GEN TERMINAL ENCLOSURE
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
IR COMBUSTIBLE GAS DETECTOR - GTE LOCAL SENSOR
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3 MS
45HGT-7A 0474 COMBUSTIBLE GAS DETECTOR - GEN COLLECTOR COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
COMBUSTIBLE GAS DETECTOR - GCC EXTRACT DUCT SENSOR
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL, INRUSH CURRENT
DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12 VDC FOR 3MS
DURATION
45HGT-7B 0474 COMBUSTIBLE GAS DETECTOR - GEN COLLECTOR COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
COMBUSTIBLE GAS DETECTOR - GCC EXTRACT DUCT SENSOR
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL, INRUSH CURRENT
DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12 VDC FOR 3MS
DURATION
45HGT-7C 0474 COMBUSTIBLE GAS DETECTOR - GEN COLLECTOR COMPARTMENT
HIGH ALARM SETTING AT 10% LEL
HIGH-HIGH ALARM SETTING AT 25% LEL
COMBUSTIBLE GAS DETECTOR - GCC EXTRACT DUCT SENSOR
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL, INRUSH CURRENT
DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12 VDC FOR 3MS
DURATION

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 19 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 20 of 67

A
SIZE DWG NO SH REV
399A4822 20 B

Device System Settings

45HT-IR-1A 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-1B 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-1C 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-1D 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-2A 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT (OUTDOOR UNITS)
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-2B 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT (OUTDOOR UNITS)
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 20 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 21 of 67

A
SIZE DWG NO SH REV
399A4822 21 B

Device System Settings

45HT-IR-2C 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT (OUTDOOR UNITS)
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
45HT-IR-2D 0474 IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT
HIGH ALARM SETTING AT 8% LEL
HIGH-HIGH ALARM SETTING AT 17% LEL
IR COMBUSTIBLE GAS DETECTOR - TC EXTRACT DUCT (OUTDOOR UNITS)
24VDC, 0.1 A 4.0MA FOR 0% LEL 20.0MA FOR 100% LEL
INRUSH CURRENT DATA: 1 AMP @ 8VDC FOR 3MS DURATION, , .9 AMP @ 12
VDC FOR 3
49IC-1 0471 INLET AIR SCREW AUGER MOTOR OVERLOAD
RATING: 15.00 A; 230 VAC; 1 PH; 50 HZ; PROTECTS 88IC-1
NORM=(1) NC-CEC; AUXILIARY CONTACTS;;
NORMALLY CLOSED-OPEN ON OVERLOAD
49WS-1 0442 WATER WASH SKID HEATER OVERLOAD
(INTEGRAL PART OF 23WS-1)
4WW 0442 WATER WASH MASTER CONTROL RELAY
CONTROL SIGNAL NAME IS L4WWX. WIRE TO MK V / MK VI. MK V / MK VI
OUTPUT SIGNAL IS DRY CONTACT.
62FP-1A 0426 FIRE PROTECTION-TIMER RESET SWITCH (FOR ALL ZONES)
NORM=(1) NO;
SWITCH TO RESET SYSTEM AFTER CO2 DISCHARGE IN ZONE 1
62FP-2A 0426 FIRE PROTECTION-CO2 TIMER RESET SWITCH (ZONE 2)
NORM=(1) NO;
SWITCH TO RESET SYSTEM AFTER CO2 DISCHARGE IN ZONE 2
62FP-3A 0426 FIRE PROTECTION-CO2 TIMER RESET SWITCH (ZONE 3)
NORM=(1) NO;
SWITCH TO RESET SYSTEM AFTER CO2 DISCHARGE IN ZONE 3
63AD-4 0419 APU LOW PRESSURE SWITCH
DECREASING: 85.00+-5.000 PSIG OR 586.1+-34.47 KPAG
APU LOW PRESSURE ALARM. INDICATES INSUFFICIENT
AIR AVAILABLE FOR NORMAL DEVICE OPERATION. OPENS TO ALARM. SIGNAL
NAME IS L63AD4. WIRE TO MKV / MK VI.
63AG-1A 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AG-1B 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 21 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 22 of 67

A
SIZE DWG NO SH REV
399A4822 22 B

Device System Settings

63AG-1C 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AG-2A 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AG-2B 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AG-2C 0436 GEAR/LOAD COMPT AIR PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-1A 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-1B 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-1C 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-2A 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-2B 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-2C 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-3 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63AT-4 0436 DIFFERENTIAL PRESSURE SWITCH
DECREASING: 0.4000 INH2O OR 0.0995 KPA
NORM=NO-CEC;
63BN-1 0417 VENT AIR PRESSURE SWITCH-#2 BEARING AREA
DECREASING: 4.500+-0.1000 INH2O OR 1.120+-0.0249 KPA
(INCREASING: 6.000+-0.3000 INH2O OR 1.493+-0.0747 KPA)
NORM=(1) NO;
63BN-2 0417 VENT AIR PRESSURE SWITCH-#2 BEARING AREA
DECREASING: 4.500+-0.1000 INH2O OR 1.120+-0.0249 KPA
(INCREASING: 6.000+-0.3000 INH2O OR 1.493+-0.0747 KPA)
NORM=(1) NO;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 22 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 23 of 67

A
SIZE DWG NO SH REV
399A4822 23 B

Device System Settings

63CA-1 0471 INLET AIR FILTER COMPRESSED AIR PRESSURE SWITCH
DECREASING: 60.00+-5.000 PSIG OR 413.7+-34.47 KPAG
NORM=(2) NO-CEC; CLOSED WHEN PRESSURIZED;
0.5A, 125VDC
63FGD-1 0422 FUEL GAS STRAINER DP SWITCH
INCREASING: 15.00+-1.000 PSID OR 103.4+-6.895 KPAD
(DECREASING: 13.75+-1.250 PSID OR 94.80+-8.618 KPAD)
NORM=(1) NC-OEC; SPDT;
63FP-11A 0426 FIRE PROTECTION-CO2 SELECTOR VLV ACTUATION PRESS SWITCH
INCREASING: 90.00+-20.00 PSIG OR 620.5+-137.9 KPAG
NORM=(2) NO; MANUAL RESET REQUIRED;
CONTACT CLOSES WHEN CO2 PRESSURE IN ZONE 1 ACTUATION LINE RISES
ABOVE PRIMARY SETTING. WIRES TO 45FTX-1 AUX RELAY PANEL.
63FP-12A 0426 FIRE PROTECTION-CO2 SELECTOR VLV ACTUATION PRESS SWITCH
INCREASING: 90.00+-20.00 PSIG OR 620.5+-137.9 KPAG
NORM=(2) NO; MANUAL RESET REQUIRED;
CONTACT CLOSES WHEN CO2 PRESSURE IN ZONE 2 ACTUATION LINE RISES
ABOVE PRIMARY SETTING. WIRES TO 45FTX-1 AUX RELAY PANEL.
63FP-13A 0426 FIRE PROTECTION-CO2 SELECTOR VLV ACTUATION PRESS SWITCH
INCREASING: 90.00+-20.00 PSIG OR 620.5+-137.9 KPAG
NORM=(2) NO; MANUAL RESET REQUIRED;
CONTACT CLOSES WHEN CO2 PRESSURE IN ZONE 3 ACTUATION LINE RISES
ABOVE PRIMARY SETTING. WIRES TO 45FTX-1 AUX RELAY PANEL.
63GCX-1 4035 CARRIER GAS - LOW PRESSURE ALARM
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
63GCX-2 4035 CALIBRATION GAS - LOW PRESSURE ALARM
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
63HF-1 0434 HYDRAULIC OIL FILTER DIFF PRESSURE ALARM
INCREASING: 100.0+-3.000 PSID OR 689.5+-20.68 KPAD
(DECREASING: 80.00+-10.00 PSID OR 551.6+-68.95 KPAD)
NORM=(1) NC-OEC;
63HF-2 0434 HYDRAULIC FILTER DIFF PRESSURE ALARM
INCREASING: 100.0+-3.000 PSID OR 689.5+-20.68 KPAD
(DECREASING: 80.00+-10.00 PSID OR 551.6+-68.95 KPAD)
NORM=(1) NC-OEC;
63HQ-1A 0434 HYDRAULIC OIL SUPPLY PRESSURE SWITCH
DECREASING: 1450+-25.00 PSIG OR 9997+-172.4 KPAG
(INCREASING: 1550+-25.00 PSIG OR 10687+-172.4 KPAG)
NORM=(1) NO-CEC;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 23 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 24 of 67

A
SIZE DWG NO SH REV
399A4822 24 B

Device System Settings

63HQ-1B 0434 HYDRAULIC OIL SUPPLY PRESSURE SWITCH
DECREASING: 1450+-25.00 PSIG OR 9997+-172.4 KPAG
(INCREASING: 1550+-25.00 PSIG OR 10687+-172.4 KPAG)
NORM=(1) NO-CEC;
63HQ-6A 0434 LOW HYDRAULIC OIL PUMP PH1-1 INLET PRESSURE
DECREASING: 10.00+-1.000 PSIG OR 68.95+-6.895 KPAG
(INCREASING: 12.00+-1.000 PSIG OR 82.74+-6.895 KPAG)
NORM=(1) NO-CEC;
63HQ-6B 0434 LOW HYDRAULIC OIL PUMP PH2-1 INLET PRESSURE
DECREASING: 10.00+-1.000 PSIG OR 68.95+-6.895 KPAG
(INCREASING: 12.00+-1.000 PSIG OR 82.74+-6.895 KPAG)
NORM=(1) NO-CEC;
63PG-1A 0477 PRIMARY GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
63PG-1B 0477 PRIMARY GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
63PG-1C 0477 PRIMARY GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
63PG-3A 0477 GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
HAZARDOUS ZONE: ZONE 2
PROTECTION METHOD: ``D`` - FLAME-PROOF
63PG-3B 0477 GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
63PG-3C 0477 GAS FUEL SYSTEM PURGE PRESSURE SWITCH
INCREASING: 50.00+-2.000 PSIG OR 344.7+-13.79 KPAG
(DECREASING: 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG)
NORM=(1) NC-OEC;
63QA-1A 0416 LUBE OIL BEARING HEADER PRESSURE SWITCH-AUX PUMP START
DECREASING: 83.00+-2.000 PSIG OR 572.3+-13.79 KPAG
(INCREASING: 91.00+-2.000 PSIG OR 627.4+-13.79 KPAG)
NORM=(1) NO-CEC;
63QA-1B 0416 LUBE OIL BEARING HEADER PRESSURE SWITCH
DECREASING: 83.00+-2.000 PSIG OR 572.3+-13.79 KPAG
(INCREASING: 91.00+-2.000 PSIG OR 627.4+-13.79 KPAG)
NORM=(1) NO-CEC;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 24 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 25 of 67

A
SIZE DWG NO SH REV
399A4822 25 B

Device System Settings

63QB-1 0434 BEARING LIFT OIL SUPPLY PRESSURE
DECREASING: 2350+-40.00 PSIG OR 16203+-275.8 KPAG
(INCREASING: 2500+-40.00 PSIG OR 17237+-275.8 KPAG)
NORM=(1) NO-CEC;
63QE-1 0416 EMERGENCY LUBE OIL PUMP RUNNING
INCREASING: 10.00+-1.000 PSIG OR 68.95+-6.895 KPAG
(DECREASING: 8.000+-1.000 PSIG OR 55.16+-6.895 KPAG)
NORM=(1) NO-CEC;
63QQ-21 0416 MAIN LUBE OIL FILTER DIFFERENTIAL PRESSURE-ALARM
INCREASING: 15.00+-1.000 PSID OR 103.4+-6.895 KPAD
(DECREASING: 12.00+-2.000 PSID OR 82.74+-13.79 KPAD)
NORM=(1) NC-OEC;
63QQ-22 0416 MAIN LUBE OIL FILTER DIFFERENTIAL PRESSURE-ALARM
INCREASING: 15.00+-1.000 PSID OR 103.4+-6.895 KPAD
(DECREASING: 12.00+-2.000 PSID OR 82.74+-13.79 KPAD)
NORM=(1) NC-OEC;
63QQ-25 0416 SEAL OIL FILTER DIFFERENTIAL PRESSURE SWITCH
INCREASING: 13.00+-1.000 PSID OR 89.63+-6.895 KPAD
(DECREASING: 11.75+-1.250 PSID OR 81.01+-8.618 KPAD)
NORM=(1) NC; SPDT;
63QT-2A 0416 LOW LUBE OIL PRESSURE
DECREASING: 8.000+-1.000 PSIG OR 55.16+-6.895 KPAG
(INCREASING: 10.00+-1.000 PSIG OR 68.95+-6.895 KPAG)
63QT-2B 0416 LOW LUBE OIL PRESSURE
DECREASING: 8.000+-1.000 PSIG OR 55.16+-6.895 KPAG
(INCREASING: 10.00+-1.000 PSIG OR 68.95+-6.895 KPAG)
63TK-1 0417 TURBINE SHELL & EXHAUST FRAME BLOWER DSCH PRESSURE SW
DECREASING: 25.00+-0.8000 INH2O OR 6.221+-0.1991 KPA
(INCREASING: 28.00+-0.8000 INH2O OR 6.968+-0.1991 KPA)
NORM=(1) NO;
63TK-2 0417 TURBINE SHELL & EXHAUST FRAME BLOWER DSCH PRESSURE SW
DECREASING: 25.00+-0.8000 INH2O OR 6.221+-0.1991 KPA
(INCREASING: 28.00+-0.8000 INH2O OR 6.968+-0.1991 KPA)
NORM=(1) NO;
63TW-1 0442 TURBINE/COMPRESSOR WASH WATER PRESSURE
DECREASING: 93.00+-2.000 PSIG OR 641.2+-13.79 KPAG
NORM=(2) NO-CEC;
63TW-2 0442 TURBINE/COMPRESSOR WASH WATER PRESSURE-PUMP TRIP
INCREASING: 4.000 INHG OR 13.55 KPA
NORM=NC-OEC;
OPENS ON INCREASING VACUUM 4 INHGV (DEC PRESS)
CLOSED AT ATMOSPHERIC PRESSURE.
65CM-1 0417 CASE TEMP. MANAGEMENT FLOW CONTROL DAMPER POSITIONER
4.0MA = 0% = 20CM-1 FULL CLOSED
20.0MA = 100% = 20CM-1 FULL OPEN

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 25 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 26 of 67

A
SIZE DWG NO SH REV
399A4822 26 B

Device System Settings

65EP-18 0417 VALVE POSITIONER FOR PCV
4 MA = 3 PSIG = 100% = VA7-2 FULL OPEN
20 MA = 15 PSIG = 0% = VA7-2 FULL CLOSED
PART OF VA7-2
65EP-19 0417 I/P CONTROLLER, VALVE POSITIONER
4 MA = 3 PSIG = 0% = VA7-3 FULL CLOSED
20 MA = 15 PSIG = 100% = VA7-3 FULL OPEN
PART OF VA7-3
65EP-3 0432 ELECTRO-PNEUMATIC TRANSDUCER
4.0MA = 100% = VA20-1 FULL OPEN
20.0MA = 0% = VA20-1 FULL CLOSED
65EP-G1P 0477 GAS FUEL PURGE VALVE POSITIONER
4.00 +-0.200 MA = 0% STROKE (FULLY CLOSED)
20.00 +- 0.200 MA = 100% STROKE (FULLY OPEN)
PART OF VA13-2
65GC-1 0422 GAS CONTROL VALVE SERVO VALVE
RATED FLOW: 1.000 GPM AT 1000 PSID
RATED FLOW: 3.785 LPM AT 6895 KPAG
65GC-2 0422 GAS CONTROL VALVE SERVO VALVE
RATED FLOW: 1.000 GPM AT 1000 PSID
RATED FLOW: 3.785 LPM AT 6895 KPAG
65GC-3 0422 GAS CONTROL VALVE SERVO VALVE
RATED FLOW: 1.000 GPM AT 1000 PSID
RATED FLOW: 3.785 LPM AT 6895 KPAG
71QH-1 0416 HIGH LUBE OIL LEVEL-ALARM
NORM=(1) NC-OEC;
INCREASING 3.000 +- 0.250`` (76.2 +- 6.35 MM)
DECREASING 1.500 +- 0.500`` (38.1 +- 12.7 MM)
71QL-1 0416 LOW LUBE OIL LEVEL-ALARM
NORM=(1) NO-CEC;
DECREASING 2.000 +- 0.250`` (-50.8 +- 6.35 MM)
INCREASING 1.500 +- 0.500`` (-38.1 +- 12.7 MM)
71QL-2 0416 LOW LUBE OIL LEVEL-ALARM
NORM=(1) NO-CEC;
DECREASING 3.000 +- 0.250`` (-76.2 +- 6.35 MM)
INCREASING 1.500 +- 0.500`` (-38.1 +- 12.7 MM)
71TW-1 0442 WATER TANK WATER LEVEL CONTROL
NORM=(2) NC-OEC;
DECREASING: 15+-1 IN H20 OR 38.09 +- 2.5 CM OF WATER
MAGNETICIC LEVEL SWITCH SET 15 INCHES ABOVE THE BOTTOM OF THE
WATER TANK.
77HT-1 0415 MAGNETIC PICKUP (OVERSPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 26 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 27 of 67

A
SIZE DWG NO SH REV
399A4822 27 B

Device System Settings

77HT-2 0415 MAGNETIC PICKUP (OVERSPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM
77HT-3 0415 MAGNETIC PICKUP (OVERSPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM
77NH-1 0415 MAGNETIC PICKUP (SPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM
77NH-2 0415 MAGNETIC PICKUP (SPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM
77NH-3 0415 MAGNETIC PICKUP (SPEED)
GAP: 0.0500+-0.0050 IN OR 1.270+-0.1270 MM
77RP-11 0415 SHAFT ANGULAR POSITION INDICATOR (KEYPHASOR) BEARING#1
80HA-FS-7 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HA-FS-9A 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HA-FS-9B 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 27 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 28 of 67

A
SIZE DWG NO SH REV
399A4822 28 B

Device System Settings

80HA-FS-9C 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HGT-FS-1 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HGT-FS-2 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HGT-FS-7A 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 28 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 29 of 67

A
SIZE DWG NO SH REV
399A4822 29 B

Device System Settings

80HGT-FS-7B 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HGT-FS-7C 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-1A 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-1B 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 29 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 30 of 67

A
SIZE DWG NO SH REV
399A4822 30 B

Device System Settings

80HT-FS-1C 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-1D 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-2A 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-2B 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 30 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 31 of 67

A
SIZE DWG NO SH REV
399A4822 31 B

Device System Settings

80HT-FS-2C 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80HT-FS-2D 0474 FLOW SWITCH
DECREASING: 2.750+-0.2000 OR 2.750+-0.2000
ASPIRATED COMBUSTIBLE GAS DETECTOR FS
DECREASING SET POINT: 2.75 CFH
INCREASING SET POINT 3.0 CFH
SET POINT TOLERANCE TBD
SET POINT UOM: CFH
NORMAL BIAS (DE-ENERGIZED) (2) NO-CEC
ALARM ON LOW FLOW
80WW-1 0442 FLOW SWITCH-WATER WASH SKID
NORM=(2) NC-OEC;
CONTACT OPENS AT 2 GPM OR 0.45 M3/HR ON INCR FLOW
WATER WASH FLOW EXISTS RELAY TO TURBINE CONTROL SYSTEM AND
CONTROL SIGNAL NAME IS L80WWN. WIRE TO MK V / MK VI.
86WWX 0442 WATER WASH SKID TRIP ALARM RELAY
CONTROL SIGNAL NAME IS L86WWX. WIRE TO MK V / MK VI.
88AD-1 0419 FAN MOTOR, APU HEAT EXCHANGER
2.000 HP; 1725 RPM; 230 VAC; 1 PH; 50 HZ;
COOLS APU HEAT EXCHANGER. MOTOR RATING SPECIFIED IS THE MAX HP
EXPECTED.
88BL-1 0436 COOLING AIR FAN MOTOR-LUBE OIL SKID
5.000 HP; 3.728 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88BL-2 0436 COOLING AIR FAN MOTOR-LUBE OIL SKID
5.000 HP; 3.728 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88BN-1 0417 COOLING AIR FAN MOTOR-#2 BEARING AREA
20.00 HP; 14.91 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
15KW
88BN-2 0417 COOLING AIR FAN MOTOR-#2 BEARING AREA
20.00 HP; 14.91 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
15KW

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 31 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 32 of 67

A
SIZE DWG NO SH REV
399A4822 32 B

Device System Settings

88BT-1 0436 COOLING AIR FAN MOTOR-TURBINE COMPARTMENT
50.00 HP; 37.28 KW; 1000 RPM; 400 VAC; 3 PH; 50 HZ;
LEFT HAND SIDE FAN MOTOR, LOOKING DOWNSTREAM
HAZARDOUS ZONE: ZONE 2
PROTECTION METHOD: `D` - FLAMEPROOF
88BT-2 0436 COOLING AIR FAN MOTOR-TURBINE COMPARTMENT
50.00 HP; 37.28 KW; 1000 RPM; 400 VAC; 3 PH; 50 HZ;
RIGHT HAND SIDE FAN MOTOR, LOOKING DOWNSTREAM
HAZARDOUS ZONE: ZONE 2
PROTECTION METHOD: `D` - FLAMEPROOF
88CM-1 0417 CASE TEMP. MANANGEMENT(CLEARANCE CONTROL)BLOWER MOTOR
50.00 HP; 37.28 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
88ES-1 0416 EMERGENCY SEAL OIL PUMP MOTOR
20.00 HP; 14.91 KW; 3000 RPM; 125 VDC;
88FP-1A 0426 FIRE PROTECTION-CO2 REFRIGERATION COMPRESSOR MOTOR
3.000 HP; 2.237 KW; 1425 RPM; 400 VAC; 3 PH; 50 HZ;
HP LISTED IS MAX VALUE. ACTUAL HP MAY BE LESS
88FP-1B 0426 REDUNDANT FP-CO2 REFRIGERATION COMPRESSOR MOTOR
3.000 HP; 2.237 KW; 1425 RPM; 400 VAC; 3 PH; 50 HZ;
HP LISTED IS MAX VALUE. ACTUAL HP MAY BE LESS
88HQ-1 0434 HYDRAULIC SUPPLY PUMP MOTOR
60.00 HP; 44.74 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88HQ-2 0434 HYDRAULIC SUPPLY PUMP MOTOR
60.00 HP; 44.74 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88IC-1 0471 INLET FILTER, DUST COLLECTION SYSTEM SCREW AUGER MOTOR
2.000 HP; 1.491 KW; 400 VAC; 3 PH; 50 HZ;
SCREW AUGER MOTOR
88QA-1 0416 AUXILIARY LUBE OIL PUMP MOTOR
125.0 HP; 93.21 KW; 2900 RPM; 400 VAC; 3 PH; 50 HZ;
90 KW FOR CE APPLICATIONS
88QA-2 0416 AUXILIARY LUBE OIL PUMP MOTOR
125.0 HP; 93.21 KW; 2900 RPM; 400 VAC; 3 PH; 50 HZ;
90 KW FOR CE APPLICATIONS
88QE-1 0416 EMERGENCY LUBE OIL PUMP MOTOR
20.00 HP; 14.91 KW; 1750 RPM; 125 VDC;
88QS-1 0416 GENERATOR(AUXILIARY) SEAL OIL PUMP MOTOR
30.00 HP; 22.37 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
88QV-1A 0416 LUBE MIST SEPARATOR OR ELIMINATOR MOTOR
5.000 HP; 3.728 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
88QV-1B 0416 LUBE MIST SEPARATOR MOTOR
5.000 HP; 3.728 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
88TG-1 0416 TURNING GEAR MOTOR
6.400 HP; 4.772 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 32 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 33 of 67

A
SIZE DWG NO SH REV
399A4822 33 B

Device System Settings

88TK-1 0417 TURBINE SHELL & EXHAUST FRAME BLOWER MOTOR
213.0 HP; 158.8 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
160 KW
88TK-2 0417 TURBINE SHELL & EXHAUST FRAME BLOWER MOTOR
213.0 HP; 158.8 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
160 KW
88TW-1 0442 TURBINE/COMPRESSOR WASH WATER PUMP MOTOR
25.00 HP; 18.64 KW; 3000 RPM; 400 VAC; 3 PH; 50 HZ;
20 HP MAY BE USED BASED ON ACTUAL PUMP PERFORMANCE.
88VG-1 0436 LOAD COMPT COOLING AIR FAN MOTOR
7.500 HP; 5.593 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88VG-2 0436 LOAD COMPT COOLING AIR FAN MOTOR
7.500 HP; 5.593 KW; 1500 RPM; 400 VAC; 3 PH; 50 HZ;
88VW-1 0442 WATER WASH UNIT VENT FAN MOTOR
0.5000 HP; 0.3728 KW; 1725 RPM; 230 VAC; 1 PH; 50 HZ;
88WS-1 0442 WATER WASH SKID SPACE HEATER BLOWER MOTOR
0.1000 HP; 0.0746 KW; 1550 RPM; 230 VAC; 1 PH; 50 HZ;
8IC-1 0471 INLET AIR SCREW AUGER MOTOR DISCONNECT
15 A
NORM=(3) NC-CEC; PROTECTS 88IC-1;
ALSO DISCONNECTS 23IC-1
90LT-1 0420 COOLING WATER VALVE POSITION REGULATOR - LO HX
4 +- 0.200 MA = 0% STROKE (B-L POSITION, FULL UP)
20 +- 0.200 MA = 100% STROKE (B-R POSITION, FULL DOWN)
90SR-1 0422 STOP/SPEED RATIO VALVE SERVO VALVE
RATED FLOW: 15.00 GPM AT 1000 PSID
RATED FLOW: 56.8 LPM AT 6895 KPAG
90TV-1 0434 INLET GUIDE VANE SERVO VALVE
RATED FLOW: 10.00 GPM AT 1000 PSIG
(38 GPM @ 6895 KPA)
94F-1A 0426 FIRE PROTECTION TRIP CONTACT (ZONE 1)
NORM=(1) NO; 125VDC CONTACT;
CONTACT IS WIRED TO 45FTX-1 AUX RELAY PANEL AND CLOSES UPON START
OF PRE-DISCHARGE TIMER.
94F-1B 0426 FIRE PROTECTION TRIP CONTACT (ZONE 1)
NORM=(1) NC-OEC; 125VDC CONTACT;
CONTACT IS WIRED TO TCP AND OPENS UPON START OF CO2 DISCHARGE.
94F-2A 0426 FIRE PROTECTION TRIP CONTACT (ZONE 2)
NORM=(1) NO; 125VDC CONTACT;
CONTACT IS WIRED TO 45FTX-1 AUX RELAY PANEL AND CLOSES UPON START
OF PRE-DISCHARGE TIMER.
94F-2B 0426 FIRE PROTECTION TRIP CONTACT (ZONE 2)
NORM=(1) NC-OEC; 125VDC CONTACT;
CONTACT IS WIRED TO TCP AND OPENS UPON START OF CO2 DISCHARGE.

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 33 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 34 of 67

A
SIZE DWG NO SH REV
399A4822 34 B

Device System Settings

94F-3A 0426 FIRE PROTECTION TRIP CONTACT (ZONE 3)
NORM=(1) NO; 125VDC CONTACT;
CONTACT IS WIRED TO 45FTX-1 AUX RELAY PANEL AND CLOSES UPON START
OF PRE-DISCHARGE TIMER.
94F-3B 0426 FIRE PROTECTION TRIP CONTACT (ZONE 3)
NORM=(1) NC-OEC; 125VDC CONTACT;
CONTACT IS WIRED TO TCP AND OPENS UPON START OF CO2 DISCHARGE.
95FP-1 0440 GENERATOR AIR GAP FLUX PROBE
95SG-2 0415 IGNITION EXCITER FOR 95SP-2
115VAC/230 VAC, 50/60HZ, 150VA MAX INPUT
1.5 MIN ON/1.5 MIN OFF/1.5 MIN ON/25 MIN OFF
95SG-3 0415 IGNITION EXCITER FOR 95SP-3
115VAC/230 VAC, 50/60HZ, 150VA MAX INPUT
1.5 MIN ON/1.5 MIN OFF/1.5 MIN ON/25 MIN OFF
95SP-2 0415 COMBUSTION CHAMBER SPARK PLUG
95SP-3 0415 COMBUSTION CHAMBER SPARK PLUG
96-TS2P-1A 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
PRESSURE TRANSMITER
STAGE TWO NOZZLE OSWC
2-WIRE, LOOP POWERED, ANALOG
96-TS2P-1B 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
PRESSURE TRANSMITER
STAGE TWO NOZZLE OSWC
2-WIRE, LOOP POWERED, ANALOG
96-TS2P-1C 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
PRESSURE TRANSMITER
STAGE TWO NOZZLE OSWC
2-WIRE, LOOP POWERED, ANALOG
96-TS2QP-1A 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S13 PRESSURE
2 WIRE, LOOP POWERED, ANALOG

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 34 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 35 of 67

A
SIZE DWG NO SH REV
399A4822 35 B

Device System Settings

96-TS2QP-1B 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S13 PRESSURE
2 WIRE, LOOP POWERED, ANALOG
96-TS2QP-1C 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S13 PRESSURE
2 WIRE, LOOP POWERED, ANALOG
96-TS3QP-1A 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S9 PRESSURE
2 WIRE, LOOP POWERED, ANALOG
96-TS3QP-1B 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S9 PRESSURE
2 WIRE, LOOP POWERED, ANALOG
96-TS3QP-1C 0417 TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
TRANSMITTER
S9 PRESSURE
2 WIRE, LOOP POWERED, ANALOG
96AP-1A 0492 BAROMETRIC PRESSURE TRANSMITTER
4.000+-0.2000 MA= 22.00 INHG OR 74.50 KPA
20.00+-0.2000 MA= 37.00 INHG OR 125.3 KPA
96AP-1B 0492 BAROMETRIC PRESSURE TRANSMITTER
4.000+-0.2000 MA= 22.00 INHG OR 74.50 KPA
20.00+-0.2000 MA= 37.00 INHG OR 125.3 KPA
96AP-1C 0492 BAROMETRIC PRESSURE TRANSMITTER
4.000+-0.2000 MA= 22.00 INHG OR 74.50 KPA
20.00+-0.2000 MA= 37.00 INHG OR 125.3 KPA
96BD-1 0492 COMPRESSOR BELLMOUTH DIFFERENTIAL PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 138.5 INH2O OR 34.46 KPA

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 35 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 36 of 67

A
SIZE DWG NO SH REV
399A4822 36 B

Device System Settings

96BH-1 0432 INLET HTG CV UPSTREAM PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
96BH-2 0432 INLET HTG CV DOWNSTREAM PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 150.0 PSIG OR 1034 KPAG
96CD-1 0417 COMPRESSOR DISCH PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
96CD-1B 0417 COMPRESSOR DISCH PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
96CD-1C 0417 COMPRESSOR DISCH PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 300.0 PSIG OR 2068 KPAG
96CM-1 0417 CASE TEMP. MANAGEMENT AIR SUPPLY PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 250.0 INH2O OR 62.21 KPA
96CM-2 0417 CASE TEMP. MANAGE. FLOW CONTROL DAMPER POSITION FEEDBACK
4.0 MA = 0% = 20CM-1 FULL CLOSED
20.0 MA = 100% = 20CM-1 FULL OPEN
96CS-1 0492 INLET DIFFERENTIAL PRESSURE TRANSMITTER
4.000+-0.2000 MA= 0.0 INH2O OR 0.0 KPA
20.00+-0.2000 MA= 11.10 INH2O OR 2.762 KPA
96EP-1 0492 EXHAUST DIFFERENTIAL PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 27.70 INH2O OR 6.893 KPA
96EP-2 0492 EXHAUST DIFFERENTIAL PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 27.70 INH2O OR 6.893 KPA
96EP-3 0492 EXHAUST DIFFERENTIAL PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 27.70 INH2O OR 6.893 KPA
96FG-1 0422 GAS FUEL UPSTREAM PRESSURE TRANSMITTER
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 600.0 PSIG OR 4137 KPAG
96FG-2A 0422 INTERSTAGE FUEL GAS PRESSURE TRANSMITTER
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 500.0 PSIG OR 3447 KPAG
96FG-2B 0422 INTERSTAGE FUEL GAS PRESSURE TRANSMITTER
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 500.0 PSIG OR 3447 KPAG
96FG-2C 0422 INTERSTAGE FUEL GAS PRESSURE TRANSMITTER
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 500.0 PSIG OR 3447 KPAG

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 36 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 37 of 67

A
SIZE DWG NO SH REV
399A4822 37 B

Device System Settings

96FLW-1 4035 FG CHROMATOGRAPH - GC A- LOW WOBBE INDEX
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
ENG MIN = 1180
ENG MAX = 1300
96FLW-2 4035 FG CHROMATOGRAPH - GC B - LOW WOBBE INDEX
SIGNAL IS DELIVERED VIA FIBER OPTIC CABLE TO MLI A315
ENG MIN = 1180
ENG MAX = 1300
96FM-4 0422 CORIOLIS FLOW METER TRANSMITTER
4.000 MA= 0.0 PPS OR 0.0 KG/SEC
20.00 MA= 50.00 PPS OR 22.68 KG/SEC
HAZARDOUS AREA: ZONE 2
PROTECTION METHOD: D - FLAMEPROOF
96GC-1 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-2 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-3 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-4 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-5 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-6 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-7 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-8 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96GC-9 0422 FUEL GAS CONTROL VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 37 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 38 of 67

A
SIZE DWG NO SH REV
399A4822 38 B

Device System Settings

96GN-1 0422 GAS FUEL NOZZLE PRESSURE RATIO TRANSMITTER
4.000 MA= -20.00 PSID OR -137.9 KPAD
20.00 MA= 120.0 PSID OR 827.4 KPAD
COMPARING PCD TO MANIFOLD PRESSURE DIFFUSION
96GN-2 0422 GAS FUEL NOZZLE PRESSURE RATIO TRANSMITTER
4.000 MA= -20.00 PSID OR -137.9 KPAD
20.00 MA= 120.0 PSID OR 827.4 KPAD
COMPARING PCD TO MANIFOLD PRESSURE DIFFUSION
96GN-3 0422 GAS FUEL NOZZLE PRESSURE RATIO TRANSMITTER
4.000 MA= -20.00 PSID OR -137.9 KPAD
20.00 MA= 120.0 PSID OR 827.4 KPAD
COMPARING PCD TO MANIFOLD PRESSURE DIFFUSION
96HF-1 0434 HYDRAULIC OIL FILTER DIFF PRESSURE TRANSMITTER
4.000 MA= 0.0 PSID OR 0.0 KPAD
20.00 MA= 150.0 PSID OR 1034 KPAD
ALARM AT 100 PSID INCREASING (689 KPA)
96HF-2 0434 HYDRAULIC OIL FILTER DELTA P TRANSMITTER
4.000 MA= 0.0 PSID OR 0.0 KPAD
20.00 MA= 150.0 PSID OR 1034 KPAD
ALARM AT 100 PSID INCREASING (689 KPA)
96HQ-1 0434 HYDRAULIC OIL SUPPLY PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 2000 PSIG OR 13790 KPAG
ALARM AT 1450 PSIG DECREASING (9997 KPA)
96QH-1 0416 LUBE OIL HEADER PRESSURE TRANSMITTER
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 100.0 PSIG OR 689.5 KPAG
96QL-1 0416 LUBE OIL TANK LEVEL TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 30.00 INH2O OR 7.465 KPA
96QQ-1 0416 LUBE OIL FILTER DELTA P TRANSMITTER
4.000 MA= 0.0 PSID OR 0.0 KPAD
20.00 MA= 30.00 PSID OR 206.8 KPAD
96QQ-2 0416 CONTROL OIL FILTER DELTA P TRANSMITTER
4.000 MA= 0.0 PSID OR 0.0 KPAD
20.00 MA= 30.00 PSID OR 206.8 KPAD
96QV-2 0416 LUBE OIL TANK AIR PRESSURE TRANSDUCER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 30.00 INH2O OR 7.465 KPA
ALARM IF TANK PRESSURE FALLS BELOW 3.6 INH20
96SR-1 0422 STOP/SPEED RATIO VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 38 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 39 of 67

A
SIZE DWG NO SH REV
399A4822 39 B

Device System Settings

96SR-2 0422 STOP/SPEED RATIO VALVE LVDT
0% STROKE = 0.7 VAC
100% STROKE = 3.5 VAC
96TD-1A 0471 DEW POINT SENSOR/TRANSMITTER
4.000+-0.5000 MA= -49.00 F OR -45.00 C
20.00+-0.5000 MA= 167.0 F OR 75.00 C
230VAC, 4-20 MA OUTPUT SIGNAL
96TF-1 0471 TURBINE INLET FILTER DIFF PRESSURE TRANSMITTER
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 10.00 INH2O OR 2.488 KPA
ALARM AT 6.00 +- 0.25 INH20 (1.49 +-0.06 KPA)
POWERED BY 24 VDC, 4-20 MA OUTPUT SIGNAL
96TF-2A 0471 TURBINE INLET FILTER DIFF PRESSURE TRANSMITTER
ALARM AT 6.00 +- 0.25 INH20 (1.49 +-0.06 KPA)
POWERED BY 24 VDC, 4-20 MA OUTPUT SIGNAL
96TF-2B 0471 TURBINE INLET FILTER DIFF PRESSURE TRANSMITTER
ALARM AT 6.00 +- 0.25 INH20 (1.49 +-0.06 KPA)
POWERED BY 24 VDC, 4-20 MA OUTPUT SIGNAL
96TH-1 0432 INLET HEATING CONTROL VALVE POSITION TRANSMITTER
4.0MA = 0% = VALVE VA20-1 FULL CLOSED
20.0MA = 100% =VALVE VA20-1 FULL OPEN
96TV-1 0434 INLET GUIDE VANE LVDT
LVDT POSITION SIGNAL = 0.6 +/- 0.09 VRMS AT FULL LVDT EXTENSION.
CALIBRATE TO PROVIDE SIGNAL OF 0.7 +/- 0.02 VRMS AT IGV FULL CLOSED
(ACTUATOR EXTENDED), AND BETWEEN 2.40 - 3.70 VRMS AT IGV FULL OPEN
(ACTUATOR RETRACTED).
96TV-2 0434 INLET GUIDE VANE LVDT
LVDT POSITION SIGNAL = 0.6 +/- 0.09 VRMS AT FULL LVDT EXTENSION.
CALIBRATE TO PROVIDE SIGNAL OF 0.7 +/- 0.02 VRMS AT IGV FULL CLOSED
(ACTUATOR EXTENDED), AND BETWEEN 2.40 - 3.70 VRMS AT IGV FULL OPEN
(ACTUATOR RETRACTED).
96VC-11 0415 SHAFT AXIAL POSN TRANSMITTER BEARING #1
96VC-12 0415 SHAFT AXIAL POSN TRANSMITTER BEARING #1
96VS-1 0440 SHAFT VOLTAGE TRANSDUCER
30 WATT MAX
VOLTAGE ALARM = 5 VOLTS
CURRENT ALARM = 4 AMPS
96WW-3 0442 PRESS TRANS, ONLINE COMPRESSOR WASH MANIFOLD SUPPLY
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 150.0 PSIG OR 1034 KPAG
96WW-4 0442 PRESS TRANS, GFC WATER INJ MANIFOLD SUPPLY
4.000+-0.2000 MA= 0.0 PSIG OR 0.0 KPAG
20.00+-0.2000 MA= 150.0 PSIG OR 1034 KPAG

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 39 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 40 of 67

A
SIZE DWG NO SH REV
399A4822 40 B

Device System Settings

ACV1-1 0434 IGV HYDRAULIC CYLINDER ACTUATOR
SLEW TIME: 4.5 +/-1.5 SECONDS
AH1-1 0434 HYDRAULIC OIL ACCUMULATOR
PRECHARGE 800 PSI DRY NITROGEN, 5 GALLONS (5516 KPA)
AL-2 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-27 0471 AC LIGHT-INLET AIR COMPARTMENT
230VAC, 50HZ
1 PH
AL-2A 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-2B 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-4 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-4A 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-4B 0416 AC LIGHT-ACCESSORY COMPARTMENT
AL-62 0442 AC LIGHT-WATER WASH SKID
AL-63 0442 AC LIGHT-WATER WASH SKID
AL-81 0442 AC LIGHT-WATER WASH SKID
AL-87 0422 AC LIGHT-GAS FUEL MODULE
AL-88 0422 AC LIGHT-GAS FUEL MODULE
APU-LIC-1 0419 APU LOCAL INDICATOR CONTROL
INCREASING: 110.0+-5.000 F OR 43.33+-2.778 C
(DECREASING: 100.0+-5.000 F OR 37.78+-2.778 C)
CONTROLS 88AD-1
APU OVER TEMPERATURE CONTROL SETTINGS
INCREASING: 145.0+-5.000 F OR 62.78+-2.778 C
DECREASING: 142.0+-5.000 F OR 61.11+- 2.778 C
CONTROLS 20AP-1
APU-TC-1 0419 APU TEMPERATURE ELEMENT, PROVIDES SIGNAL FOR APU-LIC-1
AR-2 0416 AC RECEPTACLE-ACCESSORY COMPARTMENT
AR-20 0471 AC RECEPTACLE-INLET FILTER COMPARTMENT
230 V, 50 HZ, 1 PH
GROUNDED
AR-2A 0416 AC RECEPTACLE-ACCESSORY COMPARTMENT
AR-50 0442 AC RECEPTACLE-WATER WASH SKID
ASW-10 0471 AC LIGHT SWITCH-INLET AIR COMPARTMENT
230VAC, 50 HZ,1 PH
ASW-13 0416 AC SW-ACCESSORY COMPARTMENT
ASW-13A 0416 3 WAY EXPLOSION PROOF TUMBLER SWITCH
ASW-31 0442 AC LIGHT SWITCH-WATER WASH SKID
ASW-44 0422 AC LIGHT SWITCH-GAS FUEL MODULE

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 40 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 41 of 67

A
SIZE DWG NO SH REV
399A4822 41 B

Device System Settings

AT-HL-1 0436 AIR TEMPERATURE - LUBE OIL COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-HL-2 0436 AIR TEMPERATURE - LUBE OIL COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-ID-1 0471 AMBIENT TEMPERATURE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-ID-2 0471 AMBIENT TEMPERATURE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-ID-3 0471 AMBIENT TEMPERATURE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-TC-1 0436 AIR TEMPERATURE-TURBINE COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-TC-2 0436 AIR TEMPERATURE-TURBINE COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-TC-3 0436 AIR TEMPERATURE-TURBINE COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-TC-4 0436 AIR TEMPERATURE-TURBINE COMPARTMENT
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-VS-1 0436 AIR TEMPERATURE- GAS MODULE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
AT-VS-2 0436 AIR TEMPERATURE- GAS MODULE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
BT-GJ1-1A 0440 BEARING METAL TEMP-GENERATOR BEARING #1
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ1-1
ALARMS @ 260 F
BT-GJ1-1B 0440 BEARING METAL TEMP-GENERATOR BEARING #1
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ1-1
ALARMS @ 260 F

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 41 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 42 of 67

A
SIZE DWG NO SH REV
399A4822 42 B

Device System Settings

BT-GJ1-2A 0440 BEARING METAL TEMP-GENERATOR BEARING #1
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ1-2
ALARMS @ 260 F
BT-GJ1-2B 0440 BEARING METAL TEMP-GENERATOR BEARING #1
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ1-2
ALARMS @ 260 F
BT-GJ2-1A 0440 BEARING METAL TEMP-GENERATOR BEARING #2
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ2-1
ALARMS @ 260 F
BT-GJ2-1B 0440 BEARING METAL TEMP-GENERATOR BEARING #2
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ2-1
ALARMS @ 260 F
BT-GJ2-2A 0440 BEARING METAL TEMP-GENERATOR BEARING #2
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ2-2
ALARMS @ 260 F
BT-GJ2-2B 0440 BEARING METAL TEMP-GENERATOR BEARING #2
TYPE K THERMOCOUPLE
1 ELEMENT;
ONE HALF OF DUAL ELEMENT DEVICE - BT-GJ2-2
ALARMS @ 260 F
BT-J1-1A 0415 BEARING METAL TEMP-TURBINE BEARING #1
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-J1-1B 0415 BEARING METAL TEMP-TURBINE BEARING #1
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP.
BT-J1-2A 0415 BEARING METAL TEMP-TURBINE BEARING #1
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-J1-2B 0415 BEARING METAL TEMP-TURBINE BEARING #1
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 42 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 43 of 67

A
SIZE DWG NO SH REV
399A4822 43 B

Device System Settings

BT-J2-1A 0415 BEARING METAL TEMP-TURBINE BEARING #2
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-J2-1B 0415 BEARING METAL TEMP-TURBINE BEARING #2
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
BT-J2-2A 0415 BEARING METAL TEMP-TURBINE BEARING #2
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-J2-2B 0415 BEARING METAL TEMP-TURBINE BEARING #2
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
BT-TA1-12A 0415 BEARING METAL TEMP-THRUST ACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-TA1-12B 0415 BEARING METAL TEMP-THRUST ACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
BT-TA1-6A 0415 BEARING METAL TEMP-THRUST ACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-TA1-6B 0415 BEARING METAL TEMP-THRUST ACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
BT-TI1-12A 0415 BEARING METAL TEMP-THRUST INACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-TI1-12B 0415 BEARING METAL TEMP-THRUST INACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
BT-TI1-6A 0415 BEARING METAL TEMP-THRUST INACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
BT-TI1-6B 0415 BEARING METAL TEMP-THRUST INACTIVE
TYPE K THERMOCOUPLE
2 ELEMENTS; UNGROUNDED;
NOT CONNECTED TO TCP
CK-1A 0434 CHECK VALVE
CK-1B 0434 CHECK VALVE
CK-2A 0434 CHECK VALVE

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 43 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 44 of 67

A
SIZE DWG NO SH REV
399A4822 44 B

Device System Settings

CK-2B 0434 CHECK VALVE
CT-DA-1 0415 COMPRESSOR DISCHARGE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
CT-DA-2 0415 COMPRESSOR DISCHARGE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
CT-DA-3 0415 COMPRESSOR TEMP-DISCHARGE ANNULUS
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
CT-IF-1 0415 COMPRESSOR INLET THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
CT-IF-2 0415 COMPRESSOR INLET THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
CT-IF-3 0415 COMPRESSOR TEMP-INLET FLANGE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
DHCP 4027 HYDROGEN CONTROL PANEL POWER SUPPLY
HYDROGEN CONTROL PANEL SUPPLY POWER TO BE 230 VAC 50 HZ AND 600
WATTS. THIS EQUIPMENT IS TO BE POWERED BY A UPS. REFER TO ML-G2B0
FOR ADDITIONAL ELECTRICAL CONNECTION INFORMATION.
DL-2 0416 DC LIGHT-ACCESSORY COMPARTMENT
DL-2A 0416 DC LIGHT-ACCESSORY COMPARTMENT
DL-51 0422 DC LIGHT-GAS FUEL MODULE
DL-52 0422 DC LIGHT-GAS FUEL MODULE
DT-GAC-23 0440 GENERATOR COLLECTOR-COLD AIR
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 149 F OR 65 C
DT-GAH-17 0440 GENERATOR COLLECTOR-HOT AIR
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM @ 20 C ABOVE AMBIENT
DT-GGC-10 0440 GENERATOR TEMP-COLD GAS COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 122 F
DT-GGC-11 0440 GENERATOR TEMP-COLD GAS COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 122 F

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 44 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 45 of 67

A
SIZE DWG NO SH REV
399A4822 45 B

Device System Settings

DT-GGC-12 0440 GENERATOR TEMP-COLD GAS COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 122 F
DT-GGC-13 0440 GENERATOR TEMP-COLD GAS COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 122 F
DT-GGH-15 0440 GENERATOR TEMP-HOT GAS COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 212 F
DT-GGH-16 0440 GENERATOR TEMP-HOT GAS COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 212 F
DT-GGH-18 0440 GENERATOR TEMP-HOT GAS COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 212 F
DT-GGH-19 0440 GENERATOR TEMP-HOT GAS COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 212 F
DT-GGK-24 0440 GENERATOR FRAME-COMMON COLD GAS
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALSO IDENTIFIED AS GTG-2
ALARM = 145 F OR 62.78 C
DT-GIF-41 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GIF-43 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GIF-47 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GIF-49 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 45 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 46 of 67

A
SIZE DWG NO SH REV
399A4822 46 B

Device System Settings

DT-GIF-82 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GIF-84 0440 STATOR CORE TC COLLECTOR END
TYPE E THERMOCOUPLE
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-34 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-35 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-36 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-4 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-5 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSA-6 0440 GENERATOR TEMP-STATOR COLLECTOR END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSC-20 0440 GENERATOR TEMP-STATOR CENTER
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSC-21 0440 GENERATOR TEMP-STATOR CENTER
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C
DT-GSC-22 0440 GENERATOR TEMP-STATOR CENTER
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS; GROUNDED;
ALARM = 264 F OR 129 C

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 46 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 47 of 67

A
SIZE DWG NO SH REV
399A4822 47 B

Device System Settings

DT-GSF-1 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
DT-GSF-2 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
DT-GSF-3 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
DT-GSF-31 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
KKS DESIGNATION: MKA10 CT021
DT-GSF-32 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
DT-GSF-33 0440 GENERATOR TEMP-STATOR COUPLING END
100 OHM PLATINUM (DIN 43760) RTD
2 ELEMENTS;
ALARM = 264 F OR 129 C
FB1-1 0416 FAN-LUBE OIL DEMISTER #1
FB2-1 0416 FAN-LUBE OIL DEMISTER #2
FH2-1 0434 HYDRAULIC OIL SUPPLY FILTER
FILTRATION: 3 MICRON
BETA 3 >= 200
FH2-2 0434 HYDRAULIC OIL SUPPLY FILTER
FILTRATION: 3 MICRON
BETA 3 >= 200
FH6-1 0434 IGV SERVO HYDRAULIC OIL SUPPLY FILTER
FILTRATION: 15 MICRON
FH7-1 0422 FUEL GAS SERVO HYDRAULIC OIL SUPPLY FILTER
FILTRATION: 15 MICRON ABSOLUTE
WITH INTEGRAL VISUAL REPLACEMENT INDICATOR (PDI FH7-1)
FH8-1 0422 GAS FUEL SERVO HYDRAULIC SUPPLY FILTER
FILTRATION: 15 MICRON ABSOLUTE
WITH INTEGRAL VISUAL REPLACEMENT INDICATOR (PDI FH8-1)
FH8-2 0422 GAS FUEL SERVO HYDRAULIC SUPPLY FILTER
FILTRATION: 15 MICRON ABSOLUTE
WITH INTEGRAL VISUAL REPLACEMENT INDICATOR (PDI FH8-2)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 47 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 48 of 67

A
SIZE DWG NO SH REV
399A4822 48 B

Device System Settings

FH8-3 0422 GAS FUEL SERVO HYDRAULIC SUPPLY FILTER
FILTRATION: 15 MICRON ABSOLUTE
WITH INTEGRAL VISUAL REPLACEMENT INDICATOR (PDI FH8-3)
FI-WW-1 0442 WATER WASH SKID - DETERGENT FLOW INDICATOR
0.00 GPM 0.00
FLOWTOTALIZER 4027 POWER SUPPLY
HYDROGEN FLOW TOTALIZER
120 OR 240V, 16 W, 1PH
REFER TO MLI-G2B0 FOR ADDITIONAL ELECTRICAL CONNECTION INFORMATION
FQIC-2950 4027 HYDROGEN GAS FLOW TOTALIZER
4.000 MA= 0.0 OR 0.0
20.00 MA= 125.0 OR 125.0
FUNCTION: MONITOR HYDROGEN MAKE-UP GAS CONSUMPTION.
4 MA = 0 SCFH (0 SCMH)
20 MA = 125 SCFH (3.54 SCMH)
FE-2950 IS THE FLOW ELEMENT
FTG-1A 0422 FUEL GAS TEMPERATURE SENSOR
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
FTG-1B 0422 FUEL GAS TEMPERATURE SENSOR
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
FTG-1C 0422 FUEL GAS TEMPERATURE SENSOR
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
FV-1A 0434 HYDRAULIC OIL SUPPLY ISOLATION
VALVE #1
FV-1B 0434 HYDRAULIC OIL SUPPLY ISOLATION
VALVE #2
FV-2A 0434 HYD OIL DISCHARGE ISOLATION VLV
FV-2B 0434 HYD OIL DISCHARGE ISOLATION VLV
FV-3A 0434 ISOLATION VALVE
FV-3B 0434 ISOLATION VALVE
FV-4A 0434 ACCUMULATOR ISOLATION VALVE
VALVE #1
FV-4B 0434 HYDRAULIC BYPASS VALVE
VALVE #2
FY-2971 4027 TURBINE END SCAVENGING SOLENOID
230 VAC; 50 HZ;
THIS SOLENOID VALVE IS POWERED BY THE H2 PANEL UPS. SIGNAL 20SCAV1
ENERGIZES SOLENOID VALVE FY-2971 ON THE H2 CTRL PANEL TO INCREASE
SCAVENGING OF TE AT LOW PURITY.

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 48 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 49 of 67

A
SIZE DWG NO SH REV
399A4822 49 B

Device System Settings

FY-2972 4027 COLLECTOR END GAS SOLENOID
230 VAC; 50 HZ;
THIS SOLENOID VALVE IS POWERED BY THE H2 PANEL UPS. SIGNAL 20CASE1
ENERGIZES SOLENOID VALVE FY-2972 ON THE H2 CTRL PANEL TO DIRECT
GEN CASING
GAS TO ANALYZER 1 (QT-290A)
FY-2973 4027 COLLECTOR END SCAVENGING SOLENOID
230 VAC; 50 HZ;
THIS SOLENOID VALVE IS POWERED BY THE H2 PANEL UPS. SIGNAL 20SCAV2
ENERGIZES SOLENOID VALVE FY-2973 ON THE H2 CTRL PANEL TO INCREASE
SCAVENGING OF CE AT LOW PURITY.
FY-2974 4027 COLLECTOR END GAS SOLENOID.
230 VAC; 50 HZ;
THIS SOLENOID VALVE IS POWERED BY THE H2 PANEL UPS. SIGNAL 20CASE2
ENERGIZES SOLENOID VALVE FY-2974 ON THE H2 CTRL PANEL TO DIRECT
GEN CASING
GAS TO ANALYZER 2 (QT-290B)
FY-2981 4027 CASE, PURGE, CALIBRATION SOLENOID.
230 VAC; 50 HZ;
DE-ENERGIZED STATE ALLOWS FLOW FROM GEN CASE TO FY-2972 AND FY-
2974. SIGNAL 30H2STAT3 IS A CONTROL SYSTEM CONTACT FOR CASE/CAL
PURGE STATUS
THIS SOLENOID VALVE IS POWERED BY THE H2 PANEL UPS.
G023-GC 4035 GAS CHROMATOGRAPH - POWER CONSUMPTION
SOURCE POWER SUPPLIED BY CUSTOMER
1.8 KW, 7.9 AMP, 230 VAC
SINGLE UPS SOURCE REQUIRED PER SITE
230 VAC, 1PH, 50 HZ
LF3-1 0416 LUBE OIL FILTER
FILTRATION: BETA 25 = 200
LF3-2 0416 LUBE OIL FILTER
FILTRATION: BETA 25 = 200
LF3-3 0416 MIST ELIMINATOR
LF3-5 0416 SEAL OIL FILTER
FILTRATION: BETA 25 = 200
LI-FP-1A 0426 CO2 TANK LIQUID LEVEL GAUGE
0.00 PSIG 0.00
(0.0-0.0 KPAG)
LI-QH-1 0416 LEVEL INDICATOR LUBE OIL TANK
0.00 0.00
-10 TO 6 INCHES
[-254 TO 152 MM]
LOHX-1 0416 MAIN LUBE OIL HEAT EXCHANGER
#1

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 49 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 50 of 67

A
SIZE DWG NO SH REV
399A4822 50 B

Device System Settings

LOHX-2 0416 MAIN LUBE OIL HEAT EXCHANGER
#2
LSH-2990 4027 LIQUID LEVEL DETECTOR HIGH LEVEL SWITCH
NORM=(4) NC-CEC; CONTACT OPENS ON HIGH LEVEL;
DPDT SWITCH
FUNCTION IS TO ALARM WHEN FLUID ENTERS THE LIQUID LEVEL DETECTOR
HAZARDOUS ZONE 2, PROTECTION METHOD `D`-EXPLOSION PROOF
LSH-3401 4027 SEAL OIL DRAIN HIGH LEVEL SWITCH
NORM=(4) NC-CEC; CONTACT OPENS ON HIGH LEVEL;
DPDT SWITCH. FUNCTION IS TO ALARM WHEN FLUID ENTERS LIQUID LEVEL
DETECTOR
HAZARDOUS ZONE 2, PROTECTION METHOD `D`- EXPLOSION PROOF
LSHH-2990 4027 LIQUID LEVEL DETECTOR HIGH HIGH LEVEL SWITCH
NORM=(4) NC-CEC; CONTACT OPENS ON HIGH HIGH LEVEL;
DPDT SWITCH
FUNCTION IS TO ALARM WHEN FLUID ENTERS THE LIQUID LEVEL DETECTOR
HAZARDOUS ZONE 2, PROTECTION METHOD `D`-EXPLOSION PROOF
LT-B1D-1 0416 LUBE TEMPERATURE #1 BRG DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
ALARM SETTING IS 200 F (93.3 C)
LT-B2D-1 0416 LO THERMOCOUPLE #2 BRG DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
ALARM SETTING IS 200 F (93.3 C)
LT-G1D-A 0416 LUBE SYSTEM TEMP-GENERATOR #1 BEARING DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
ALARM SETTING IS 200 F (93.3 C)
LT-G1D-B 0416 LUBE SYSTEM TEMP-GENERATOR #1 BEARING DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
(SPARE)
LT-G2D-A 0416 LUBE SYSTEM TEMP-GENERATOR #2 BEARING DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
ALARM SETTING IS 200 F (93.3 C)
LT-G2D-B 0416 LUBE SYSTEM TEMP-GENERATOR #2 BEARING DRAIN
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
(SPARE)
LT-OT-1A 0416 LUBE OIL THERMOCOUPLE LUBE OIL TANK
TYPE K THERMOCOUPLE
HIGH IMMERSION HEATER TEMPERATURE

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 50 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 51 of 67

A
SIZE DWG NO SH REV
399A4822 51 B

Device System Settings

LT-OT-1B 0416 LUBE OIL THERMOCOUPLE LUBE OIL TANK
TYPE K THERMOCOUPLE
HIGH IMMERSION HEATER TEMPERATURE
LT-OT-1C 0416 LUBE OIL THERMOCOUPLE LUBE OIL TANK
TYPE K THERMOCOUPLE
HIGH IMMERSION HEATER TEMPERATURE
LT-OT-3 0416 LUBE OIL TANK THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
LOW LUBE OIL TANK TEMPERATURE
- IMMERSION HEATERS ON AT 79 F (26 C)
- START PERMISSIVE LOCKOUT AT OR BELOW 75 F (24 C)
LT-OT-4 0416 LUBE OIL TANK THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
LOW LUBE OIL TANK TEMPERATURE
- IMMERSION HEATERS ON AT 79 F (26 C)
- START PERMISSIVE LOCKOUT AT OR BELOW 75 F (24 C)
LT-TH-1 0416 LUBE SYSTEM TEMP-TURBINE HEADER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
HIGH OIL TEMPERATURE: TRIPLE REDUNDANT (LT-TH-1, 2 & 3)
- ALARM AT 165 F (73.9 C)
- TRIP AT 175F (79.4 C)
LT-TH-2 0416 LUBE SYSTEM TEMP-TURBINE HEADER-TRIP
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
HIGH OIL TEMPERATURE: TRIPLE REDUNDANT (LT-TH-1, 2 & 3)
- ALARM AT 165 F (73.9 C)
- TRIP AT 175F (79.4 C)
LT-TH-3 0416 LUBE SYSTEM-TURBINE HEADER TEMP-TRIP
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
HIGH OIL TEMPERATURE: TRIPLE REDUNDANT (LT-TH-1, 2 & 3)
- ALARM AT 165 F (73.9 C)
- TRIP AT 175F (79.4 C)
MG1-1 0422 GAS FUEL NOZZLE
DIFFUSION
MG1-2 0422 GAS FUEL NOZZLE
PM1
MG1-3 0422 GAS FUEL NOZZLE
PM4
MG2-4 0422 CORIOLIS GAS FUEL FLOW METER

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 51 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 52 of 67

A
SIZE DWG NO SH REV
399A4822 52 B

Device System Settings

MIC-292 4027 H2 DEW POINT SENSOR LOCATED IN H2 CONTROL PANEL
4MA=-148F OR -100C
20MA=68F OR 20 C
4MA= -148F AND 20MA= 68 F, SIGNAL TO BE INTEGRATED WITH THE TCP
HIGH ALARM AT 32 F INCREASING, HIGH-HIGH ALARM SET AT 68F INCREASING
PDI-FG-3 0422 GAS FUEL STRAINER DIFFERENTIAL PRESSURE INDICATOR
0.00 0.00
0.0 - 25.0 PSID
(0.0-172.4 KPAD)
PDI-HQ-4 0434 IGV HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE INDICATOR
0.00 0.00
PDI-QQ-21 0416 LUBE OIL FILTER DIFFERENTIAL PRESSURE INDICATOR
0.00 PSID 25.00
(0.0-172.4 KPAD)
PDI-QQ-22 0416 LUBE OIL FILTER DIFFERENTIAL PRESSURE INDICATOR
0.00 PSID 25.00
(0.0-172.4 KPAD)
PDI-QQ-25 0416 SEAL OIL FILTER DIFFERENTIAL PRESSURE INDICATOR
0.00 PSID 25.00
(0.0-172.4 KPAD)
PDI-TF-CF 0471 PRESSURE DIFFERENTIAL INDICATOR
0.00 10.00
0-10 IN. W.C [0-2.49 KPA]
PDI-TF-OF 0471 OVERALL FILTERHOUSE PRESSURE DROP
0.00 10.00
0-10 IN. W.C [0-2.49 KPA]
PDI-TF-SF 0471 SELF CLEANING FILTER PRESSURE INDICATOR
0.00 10.00
0-10 IN. W.C [0-2.49 KPA]
PDS-TF-1A 0471 PRESSURE DIFFERENTIAL SWITCH
0.00 10.00
NO INTERFACE WITH TCP
0 - 10 IN. W.C. [0-2.49 KPA]
PDSL-3402 4027 SEAL OIL DIFFERENTIAL PRESSURE LOW SWITCH
DECREASING: 4.500 PSID OR 31.03 KPAD
NORM=(2) NC-CEC;
FUNCTION: ALARM
NOTE: SWITCH MUST BE COMPENSATED IN THE FIELD SINCE THE HGF AND
HSF-2 SENSING LINES ARE AT DIFFERENT ELEVATIONS.
DEAD BAND = .35
OPENS TO ALARM LOW DP

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 52 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 53 of 67

A
SIZE DWG NO SH REV
399A4822 53 B

Device System Settings

PDSL-3406 4027 SEAL OIL DIFF PRESSURE LOW-LOW, START DC PUMP
DECREASING: 3.500 PSID OR 24.13 KPAD
FUNCTION: START DC PUMP
NOTE: SWITCH MUST BE COMPENSATED IN THE FIELD SINCE THE HGF & HSF-2
SENSING LINES ARE AT DIFFERENT ELEVATIONS.
DEAD BAND = 0.98 TO 1.9 PSID
PDT-292 4027 GENERATOR ROTOR FAN PRESSURE DIFFERENTIAL
4.000 MA= 0.0 INH2O OR 0.0 KPA
20.00 MA= 30.00 INH2O OR 7.465 KPA
FUNCTION: ALARM AT 12 IN H2O (2.99 KPA)
PDT-3402 4027 SEAL OIL DIFFERENTIAL PRESSURE, SEAL OIL VS GAS PRESSURE
4.000 MA= 0.0 PSID OR 0.0 KPAD
20.00 MA= 15.00 PSID OR 103.4 KPAD
FUNCTION: MONITOR /ALARM
ALARM AT 3.5 TO INDICATE DC PUMPS MAY HAVE STARTED, ALARM AT 4.5 FOR
LOW DP AND ALARM AT 8.5 FOR HIGH DP.
PDCV-3401 CONTROL VALVE SET TO 5.5 PSID
PH1-1 0434 MAIN HYDRAULIC OIL SUPPLY PUMP
32 GPM @ 2750 PSIG (18961 KPA)
MAX VOLUME STOP SET FOR MAXIMUM VOLUME CAPACITY
PH2-1 0434 AUXILIARY HYDRAULIC OIL SUPPLY PUMP
32 GPM @ 2750 PSIG (18961 KPA)
MAX VOLUME STOP SET FOR MAXIMUM VOLUME CAPACITY
PI-AP-1 0419 APU PRESSURE INDICATOR - PREREGULATOR
0.00 PSIG 300.00
0 - 2068 KPAG
PI-AP-2 0419 APU PRESSURE INDICATOR - DRYER INLET
0.00 PSIG 300.00
0 - 2068 KPAG
PI-AP-3 0419 APU PRESSURE INDICATOR - DRYER DISCHARGE
0.00 PSIG 160.00
0 - 1103 KPAG
PI-CA-2 0471 PRESSURE INDICATOR
0.00 PSIG 150.00
(0.0-1034 KPAG)
PRESSURE INDICATOR FOR SELF CLEANING AIR SUPPLY
PI-CW-4 0420 COOLING WATER PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-CW-5 0420 COOLING WATER PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 53 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 54 of 67

A
SIZE DWG NO SH REV
399A4822 54 B

Device System Settings

PI-D5 0422 FUEL GAS PRESSURE INDICATOR
0.00 PSIG 600.00
(0.0-4137 KPAG)
PI-FG-1 0422 GAS FUEL SUPPLY PRESSURE INDICATOR
0.00 PSIG 600.00
(0.0 - 4137 KPAG)
PI-FG-2 0422 GAS FUEL INTERVALVE (P2) PRESSURE INDICATOR
0.00 PSIG 600.00
(0.0 - 4137 KPAG)
PI-FP-1A 0426 CO2 TANK PRESSURE INDICATOR
0.00 PSIG 0.00
(0.0-0.0 KPAG)
PI-GC-1 4035 GAS CHROMATOGRAPH SAMPLE PRESSURE GAUGE - 1
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-GC-2 4035 GAS CHROMATOGRAPH SAMPLE PRESSURE GAUGE - 2
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-HQ-1 0434 HYD PUMP #1 PRESSURE DISCHARGE INDICATOR
0.00 PSIG 6000.00
(0.0-41369 KPAG)
PI-HQ-2 0434 HYD PUMP #2 PRESSURE DISCHARGE INDICATOR
0.00 PSIG 6000.00
(0.0-41369 KPAG)
PI-HQ-3 0434 HYDRAULIC LOW PRESSURE INDICATOR
0.00 PSIG 2000.00
(0.0-13790 KPAG)
PI-HQ-6A 0434 HYD PUMP #1 PRESSURE INLET INDICATOR
0.00 PSIG 160.00
(0.0-1103 KPAG)
PI-HQ-6B 0434 HYD PUMP #2 PRESSURE INLET INDICATOR
0.00 PSIG 160.00
(0.0-1103 KPAG)
PI-PG-1 0477 PRESSURE INDICATOR
0.00 PSIG 160.00
(0.0-1103 KPAG)
PI-PM1 0422 FUEL GAS PRESSURE INDICATOR
0.00 PSIG 600.00
(0.0 - 4137 KPAG)
PI-PM4 0422 FUEL GAS PRESSURE INDICATOR
0.00 PSIG 600.00
(0.0 - 4137 KPAG)
PI-QA-1 0416 MAIN LUBE OIL PUMP PRESSURE INDICATOR
0.00 PSIG 200.00
(0.0-1379 KPAG)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 54 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 55 of 67

A
SIZE DWG NO SH REV
399A4822 55 B

Device System Settings

PI-QA-1A 0416 LUBE OIL HEADER PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-QA-2 0416 LUBE OIL PUMP#2 PRESSURE INDICATOR
0.00 PSIG 200.00
(0.0-1379 KPAG)
PI-QB-1 0434 LIFT OIL PRESSURE INDICATOR
0.00 PSIG 6000.00
(0.0-41369 KPAG)
PI-QE-1 0416 EMERGENCY LUBE OIL PUMP PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-QS-1 0416 SEAL OIL PUMP PRESSURE INDICATOR
0.00 PSIG 200.00
(0.0-1379 KPAG)
PI-QS-2 0416 SEAL OIL PUMP PRESSURE INDICATOR
0.00 PSIG 200.00
(0.0-1379 KPAG)
PI-QT-2A 0416 GENERATOR BEARING LUBE OIL PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-QT-2B 0416 GENERATOR BEARING LUBE OIL PRESSURE INDICATOR
0.00 PSIG 60.00
(0.0-413.7 KPAG)
PI-QV-1 0416 MIST ELIMINATOR FILTER HOUSE PRESSURE INDICATOR
0.00 0.00
0.0 - 50 INCHES H2O
[0.0 - 1270 MM H2O]
PI-WW-1 0442 WATER WASH SKID PRESSURE INDICATOR
0.00 PSIG 200.00
(0.0-1379 KPAG)
PI-WW-10 0442 PRESSURE GAUGE - WATER WASH
0.00 PSIG 200.00
(0.0-1379 KPAG)
PI-WW-11 0442 PRESSURE GAUGE - WATER WASH
0.00 PSIG 100.00
(0.0-689.5 KPAG)
PI-WW-12 0442 PRESSURE GAUGE - WATER WASH
0.00 PSIG 100.00
(0.0-689.5 KPAG)
PI-WW-13 0442 PRESSURE GAUGE - WATER WASH
0.00 PSIG 100.00
(0.0-689.5 KPAG)
PQ1-1 0416 LUBE OIL MAIN PUMP
RATED FLOW: 1050 GPM AT 112 PSIG (2900 RPM)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 55 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 56 of 67

A
SIZE DWG NO SH REV
399A4822 56 B

Device System Settings

PQ1-2 0416 LUBE OIL MAIN PUMP
RATED FLOW: 1050 GPM AT 112 PSIG (2900 RPM)
PQ2-1 0416 LUBE OIL EMERGENCY PUMP
RATED FLOW: 600.0 GPM AT 30 PSIG (1750 RPM)
PQ3-1 0416 SEAL OIL PUMP
RATED FLOW: 118.0 GPM AT 110 PSIG (2900 RPM)
PQ3-2 0416 SEAL OIL PUMP
RATED FLOW: 65.00 GPM AT 90 PSIG (2900 RPM)
PS-3404 4027 SEAL OIL INLET PRESS LOW, START DC PUMP
DECREASING: 90.00 PSIG OR 620.5 KPAG
FUNCTION: START DC PUMP
DEAD BAND = 0.85 TO 2.9 PSIG (0.0586 TO 0.1999 BARG)
PSL-2930 4027 H2 SUPPLY PRESSURE LOW
DECREASING: 110.0 PSIG OR 758.4 KPAG
(INCREASING: 125.0 PSIG OR 861.8 KPAG)
NORM=(1) NC-CEC; CONTACT OPENS ON LOW PRESSURE;
H2 SUPPLY PRESSURE LOW ALARM.
DEAD BAND = 0.2 TO 1 PSIG
HAZARDOUS ZONE 2 PROTECTION METHOD `D` FLAME PROOF
PT-2950 4027 GENERATOR GAS PRESSURE
4.000 MA= 0.0 PSIG OR 0.0 KPAG
20.00 MA= 100.0 PSIG OR 689.5 KPAG
LOW PRESSURE ALARM AT 58 PSIG.
HIGH PRESSURE ALARM AT 64 PSIG.
HAZARDOUS ZONE 2 PROTECTION METHOD `D` FLAME PROOF
PT-G1-1 0422 GAS FUEL PURGE THERMOCOUPLE
TYPE K THERMOCOUPLE
LOCATED ON DIFFUSION GAS MAINFOLD
PT-G1-2 0422 GAS FUEL PURGE THERMOCOUPLE
TYPE K THERMOCOUPLE
LOCATED ON DIFFUSION GAS MAINFOLD
PT-G1-3 0422 GAS FUEL PURGE THERMOCOUPLE
TYPE K THERMOCOUPLE
LOCATED ON DIFFUSION GAS MAINFOLD
QT-290A 4027 CELL #1 TRANSMITTER SIGNAL
4 MA - 70% H2; 20 MA - 100% H2, FOR H2 IN AIR
TE LOW LOW PURITY RUNBACK SETTING - 80% H2 DEC
TE LOW PURITY INCREASE SCAV - 85% H2 DEC (87% INC)
CASE LOW LOW PURITY RUNBACK SETTING - 90% H2 DEC
CASE LOW PURITY ALARM - 95% H2 DEC (98% H2 INC)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 56 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 57 of 67

A
SIZE DWG NO SH REV
399A4822 57 B

Device System Settings

QT-290B 4027 CELL #2 TRANSMITTER SIGNAL
4 MA - 70% H2; 20 MA - 100% H2, FOR H2 IN AIR
CE LOW LOW PURITY RUNBACK SETTING - 80% H2 DEC
CE LOW PURITY INCREASE SCAV - 85% H2 DEC (87% INC)
CASE LOW LOW PURITY RUNBACK SETTING - 90% H2 DEC
CASE LOW PURITY ALARM - 95% H2 DEC (98% H2 INC)
RS-485-1 4035 SERIAL PORT
FOR CUSTOMER USE
RS-485-2 4035 SERIAL PORT
FOR CUSTOMER USE
SLA-1C 0426 FIRE ALARM STROBE & HORN (ACCESSORY COMPT)
24 VDC
EXTERNAL STROBE/HORN
(GAS COMP/ ACCESS.MODULE-ZONE 1)
SLA-1D 0426 FIRE ALARM STROBE & HORN (ACCESSORY COMPT)
24 VDC
INTERNAL STROBE/HORN
(GAS COMP. - ACCESS.MODULE-ZONE 1)
SLA-3A 0426 FIRE ALARM STROBE & HORN (ACCESSORY MODULE)
24 VDC
EXTERNAL STROBE/HORN
(LUBE/HYDRAULIC COMP.-ACCESS.MODULE-ZONE 3)
SLA-3B 0426 FIRE ALARM STROBE & HORN (ACCESSORY MODULE)
24 VDC
EXTERNAL STROBE/HORN
(LUBE/HYDRAULIC COMP.-ACCESS.MODULE-ZONE 3)
SLA-3C 0426 FIRE ALARM STROBE & HORN
24 VDC
INTERNAL STROBE/HORN
(LUBE/HYDRAULIC COMP.-ACCESS.MODULE-ZONE 3)
SLA-3D 0426 FIRE ALARM STROBE & HORN
24 VDC
INTERNAL STROBE/HORN
(LUBE/HYDRAULIC COMP.-ACCESS.MODULE-ZONE 3)
SLT-1A 0426 FIRE ALARM STROBE & HORN (TURBINE COMPT)
24 VDC
EXTERNAL STROBE/HORN
(TURBINE COMPT-ZONE 1)
SLT-1B 0426 FIRE ALARM STROBE & HORN (TURBINE COMPT)
24 VDC
EXTERNAL STROBE/HORN
(TURBINE COMPT-ZONE 1)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 57 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 58 of 67

A
SIZE DWG NO SH REV
399A4822 58 B

Device System Settings

TI-AP-1 0419 APU TEMPERATURE INDICATOR
0.00 F 250.00
0 - 121.1 C
TI-QA-1 0416 LUBE OIL HEADER TEMPERATURE INDICATOR
20.00 F 240.00
(-6.667-115.6 C)
TI-QL-1 0416 LUBE OIL TANK TEMPERATURE INDICATOR
20.00 F 240.00
(-6.667-115.6 C)
TI-WW-1 0442 WATER WASH TANK TEMPERATURE INDICATOR
0.00 F 250.00
TT-CM-1 0417 CASE TEMP. MANAGEMENT AIR SUPPLY TEMP. TRANS.

100 OHM PLATINUM (MINCO PB) RTD

1 ELEMENT; UNGROUNDED;
4.0 MA = -58 F OR -50 C
20.0 MA = 302 F OR 150 C
TT-IB-1 0415 TURBINE TEMP-INNER BARREL
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-IB-2 0415 TURBINE TEMP-INNER BARREL
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-IB-3 0415 TURBINE TEMP-INNER BARREL
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-S13-1 0417 THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
STAGE 13 FLOW TEMPERATURE
TT-S2Q-2 0417 THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
EJECTOR EXIT TEMPERATURE
TT-S2Q-3 0417 THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
S2N SUPPLY TEMPERATURE (WYE CONNECTION LHS)
TT-S2Q-4 0417 THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
S2N SUPPLY TEMPERATURE (WYE CONNECTION RHS)

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 58 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 59 of 67

A
SIZE DWG NO SH REV
399A4822 59 B

Device System Settings

TT-S9-1 0417 THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
STAGE 9 FLOW TEMPERATURE
TT-TC-1 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-10 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-11 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-12 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-13 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-14 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-15 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-16 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-2 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-3 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-4 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-5 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-6 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 59 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 60 of 67

A
SIZE DWG NO SH REV
399A4822 60 B

Device System Settings

TT-TC-7 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-8 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-TC-9 0415 TURBINE CASING THERMOCOUPLE - 1ST STG SHROUD
TYPE K THERMOCOUPLE
UNGROUNDED;
TT-WS1AO-1 0415 TURBINE TEMPERATURE-WHEELSPACE 1ST STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS1AO-2 0415 TURBINE TEMPERATURE-WHEELSPACE 1ST STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS1FI-1 0415 TURBINE TEMPERATURE-WHEELSPACE 1ST STG FWD INNER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS1FI-2 0415 TURBINE TEMPERATURE-WHEELSPACE 1ST STG FWD INNER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS2AO-1 0415 TURBINE TEMPERATURE-WHEELSPACE 2ND STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS2AO-2 0415 TURBINE TEMPERATURE-WHEELSPACE 2ND STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS2FO-1 0415 TURBINE TEMPERATURE-WHEELSPACE 2ND STG FWD OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS2FO-2 0415 TURBINE TEMPERATURE-WHEELSPACE 2ND STG FWD OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS3AO-1 0415 TURBINE TEMPERATURE-WHEELSPACE 3RD STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS3AO-2 0415 TURBINE TEMPERATURE-WHEELSPACE 3RD STG AFT OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS3FO-1 0415 TURBINE TEMPERATURE-WHEELSPACE 3RD STG FWD OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-WS3FO-2 0415 TURBINE TEMPERATURE-WHEELSPACE 3RD STG FWD OUTER
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 60 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 61 of 67

A
SIZE DWG NO SH REV
399A4822 61 B

Device System Settings

TT-XD-1 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-10 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-11 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-12 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-13 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-14 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-15 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-16 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-17 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-18 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-19 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-2 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-20 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-21 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-22 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 61 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 62 of 67

A
SIZE DWG NO SH REV
399A4822 62 B

Device System Settings

TT-XD-23 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-24 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-25 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-26 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-27 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-28 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-29 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-3 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-30 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-31 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-4 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-5 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-6 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-7 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
TT-XD-8 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 62 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 63 of 67

A
SIZE DWG NO SH REV
399A4822 63 B

Device System Settings

TT-XD-9 0415 EXHAUST TEMPERATURE THERMOCOUPLE
TYPE K THERMOCOUPLE
1 ELEMENT; UNGROUNDED;
VA13-1 0477 FUEL GAS SYSTEM PURGE VALVE
NORM=CLOSED; VALVE TO CLOSE IN 4 SECONDS MAX
VA13-13 0477 FUEL GAS SYSTEM PURGE VALVE
NORM=OPEN
PM4 VENT VALVE
VA13-15 0422 GAS FUEL VENT VALVE
NORM=NO
VA13-18 0422 GAS FUEL VENT VALVE
NORM=NO
VA13-2 0477 FUEL GAS SYSTEM PURGE VALVE
NORM=CLOSED; VALVE TO CLOSE IN 4 SECONDS MAX
VA13-5 0477 GAS FUEL SYSTEM PURGE VALVE
NORM=CLOSED; VALVE TO CLOSE IN 4 SECONDS MAX
VA13-6 0477 GAS FUEL SYSTEM PURGE VALVE
NORM=CLOSED; VALVE TO CLOSE IN 4 SECONDS MAX
VA13-8 0477 FUEL GAS SYSTEM PURGE VENT VALVE
NORM=OPEN
D5 VENT VALVE
VA16-1 0442 OFF-LINE COMPRESSOR WASH WATER INJ (PNEUMATIC) VALVE
NORMAL = CLOSED; ENERGIZE TO OPEN
REQUIRES 80 PSIG (MINIMUM) INSTRUMENT AIR FOR ACTUATION
VA16-3 0442 ON-LINE COMPRESSOR WASH WATER INJ (PNEUMATIC) VALVE
NORMAL = CLOSED; ENERGIZE TO OPEN
REQUIRES 80 PSIG (MINIMUM) INSTRUMENT AIR FOR ACTUATION
VA16-4 0442 GFC WATER INJ (PNEUMATIC) VALVE
NORMAL = CLOSED; ENERGIZE TO OPEN
REQUIRES 80 PSIG (MINIMUM) INSTRUMENT AIR FOR ACTUATION
VA2-1 0417 COMPRESSOR BLEED VALVE
FAILED POSITION = OPEN
VA2-2 0417 COMPRESSOR BLEED VALVE
FAILED POSITION = OPEN
VA2-3 0417 COMPRESSOR BLEED VALVE
FAILED POSITION = OPEN
VA2-4 0417 COMPRESSOR BLEED VALVE
FAILED POSITION = OPEN

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 63 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 64 of 67

A
SIZE DWG NO SH REV
399A4822 64 B

Device System Settings

VA20-1 0432 INLET HEATING CONTROL VALVE
4.0 INCH STROKE
LINEAR TRIM CHARACTERISTIC
10.0 INCH ANSI FLANGE CONNECTION
FAILED POSITION = OPEN
VA32-1 0420 COOLING WATER CONTROL VALVE-LUBE OIL COOLER FLOW
SET 130 +- 3.000F OR 54.44 +- 1.666C
VA36-1 0477 FUEL GAS SYSTEM PURGE VALVE ACTUATOR QUICK EXH VALVE
PART OF VA13-1; VALVE TO CLOSE IN 4 SECONDS MAX
VA36-10 0477 3-WAY PILOT OPERATED QUICK EXHAUST VALVE
PART OF VA13-6
VALVE TO CLOSE IN 4 SECONDS MAX
VA36-2 0477 FUEL GAS SYSTEM PURGE VALVE ACTUATOR QUICK EXH VALVE
PART OF VA13-2; VALVE TO CLOSE IN 4 SECONDS MAX
VA36-9 0477 FUEL GAS SYSTEM PURGE VALVE ACTUATOR QUICK EXHAUST VALVE
PART OF VA13-5
VA40-1 0432 INLET HEATING CONTROL VALVE VOLUME BOOSTER
VA42-1 0432 INLET BLEED HEAT QUICK EXHAUSTER VALVE
VA7-2 0417 CONTROL VALVE
BYPASS FLOW CONTROL
FAILED POSITION = OPEN
VA7-3 0417 CONTROL VALVE
SUCTION ISOLATION FLOW CONTROL
FAILED POSITION = CLOSED
VAB1-1 0434 HYDRAULIC OIL SYSTEM AIR BLEED VALVE (MAIN)
VAB2-1 0434 HYDRAULIC OIL SYSTEM AIR BLEED VALVE (AUX)
VAD-2 0419 Air Processing Unit Drain Valve
1 PH
230 VAC; 50 HZ;
ELECTRONIC SOLENOID DRAIN VALVE OPERATED BY TIMER.
VCK7-1 0417 TURBINE SHELL & EXHAUST FRAME BLOWER CHECK VALVE
VCK7-3 0417 TURBINE SHELL COOLING AIR BLOWER CHECK VALVE
VGC-1 0422 FUEL GAS CONTROL VALVE
SLEW TIME = 1.00 +/-0.150 SECONDS
3.00 IN. MAXIMUM STROKE
HYDRAULIC EFFECTIVE AREA 2.54 IN^2
D5 CIRCUIT - GAS CONTROL VALVE
VGC-2 0422 FUEL GAS CONTROL VALVE
SLEW TIME = 1.000 +/-0.150 SECONDS
3.0 IN. MAXIMUM STROKE
HYDRAULIC EFFECTIVE AREA 2.54 IN^2
PM1 CIRCUIT - GAS CONTROL VALVE

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 64 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 65 of 67

A
SIZE DWG NO SH REV
399A4822 65 B

Device System Settings

VGC-3 0422 FUEL GAS CONTROL VALVE
SLEW TIME = 1.00 +/-0.150 SECONDS
3.00 IN. MAXIMUM STROKE
HYDRAULIC EFFECTIVE AREA 2.54 IN^2
PM2 CIRCUIT - GAS CONTROL VALVE
VH3-1 0434 INLET GUIDE VANE DUMP VALVE
VH5-1 0422 GAS FUEL DUMP VALVE-STOP/SPEED RATIO VALVE
VH5-2 0422 GAS FUEL DUMP VALVE-CONTROL VALVE
VH5-3 0422 GAS FUEL DUMP VALVE-CONTROL VALVE
VH5-4 0422 GAS FUEL DUMP VALVE-CONTROL VALVE
VM15-1 0432 INLET HEATING ISOLATION VALVE
10.0 INCH ANSI FLANGE CONNECTION
MANUAL BUTTERFLY VALVE
NORMAL POSITION = OPEN
VPR17-3 0417 PRESSURE REGULATOR
SET 80.00 PSIG OR 551.6 KPAG
ACTUATION AIR
PART OF VA7-2
VPR17-4 0417 PRESSURE REGULATOR
SET 15.00 PSIG OR 103.4 KPAG
SIGNAL AIR
PART OF VA7-2
VPR17-5 0417 PRESSURE REGULATOR
SET 80.00 PSIG OR 551.6 KPAG
ACTUATION AIR
PART OF VA7-3
VPR17-6 0417 PRESSURE REGULATOR
SET 15.00 PSIG OR 103.4 KPAG
SIGNAL AIR
PART OF VA7-3
VPR2-1 0416 LUBE OIL HEADER PRESSURE REGULATOR VALVE
SET 33.00+-2.000 PSIG OR 227.5+-13.79 KPAG
VPR3-1 0434 COMPENSATOR-HYDRAULIC OIL SUPPLY PUMP (IN PUMP)
SET 2750+-50.00 PSIG OR 18961+-344.7 KPAG
LOW PRESSURE SETTING: 1800 PSIG
VPR3-2 0434 COMPENSATOR-HYDRAULIC OIL SUPPLY AUX PUMP
SET 2750+-50.00 PSIG OR 18961+-344.7 KPAG
LOW PRESSURE SETTING: 1800 PSIG
VPR4-3 0434 HYDRAULIC SUPPLY PRESSURE REGULATING VALVE #1
SET 1625+-25.00 PSIG OR 11204+-172.4 KPAG
VPR4-4 0434 HYDRAULIC SUPPLY PRESSURE REGULATING VALVE #2
SET 1625+-25.00 PSIG OR 11204+-172.4 KPAG

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 65 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 66 of 67

A
SIZE DWG NO SH REV
399A4822 66 B

Device System Settings

VPR41-1 0432 TURBINE IAH CONTROL VALVE I/P INST AIR PRESSURE REG
SET 45.00+-2.000 PSIG OR 310.3+-13.79 KPAG
20TH-1 TRIP SOLENOID MUST BE ENERGIZED TO SET VPR41-1 PRESSURE
OUTPUT WITH GAGE
VPR54-22 0477 REGULATOR - GAS FUEL PURGE CONTROL VALVE
SET 90.00+-2.000 PSIG OR 620.5+-13.79 KPAG
PART OF VA13-2
VPR54-3A 0477 FILTER AIR PRESSURE REGULATOR
FILTER AIR PRESSURE REGULATOR
SET AT 85 +/- 5 PSIG OR 586 +/- 34.5 KPA
PRIMARY GAS PURGE VALVES
VPR64-2 0420 COOLING WATER CONTROL VALVE-AIR SUPPLY REG VALVE
SET 35.00+-3.000 PSIG OR 241.3+-20.68 KPAG
VPR67-1 0419 AIR FILTER BLOWDOWN REGULATOR VALVE
SET 110.0+-5.000 PSIG OR 758.4+-34.47 KPAG
VPR74-1 0442 PRESS REGULATOR, ONLINE COMPRESSOR WASH MANIFOLD SUPPLY
80 PSIG +/- 5 PSIG
(551.58 KPAG +/- 34.473 KPAG)
VPR76-1 4035 FUEL GAS SAMPLE PRESSURE REGULATING VALVE
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
VPR76-2 4035 FUEL GAS SAMPLE PRESSURE REGULATING VALVE
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
VPR77-1 4035 CARRIER GAS - PRESSURE REGULATING VALVE
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
VPR78-1 4035 CALIBRATION GAS - PRESSURE REGULATING VALVE
SET TO VENDOR REQUIREMENTS
REFER TO SERVICE MANUAL
VQC-1 0434 VARIABLE FLOW CONTROL VALVE
GT #1 BRG. LIFT OIL
VQC-2 0434 VARIABLE FLOW CONTROL VALVE
GT #1 BRG. LIFT OIL
VQC-3 0434 VARIABLE FLOW CONTROL VALVE
GT #2 BRG. LIFT OIL
VQC-4 0434 VARIABLE FLOW CONTROL VALVE
GT #2 BRG. LIFT OIL
VQC-5 0434 VARIABLE FLOW CONTROL VALVE
GENERATOR BRG. LIFT OIL - TURBINE END
VQC-6 0434 VARIABLE FLOW CONTROL VALVE
GENERATOR BRG. LIFT OIL - COLLECTOR END

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 66 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR

DWG Number 399A4822 Rev B Released 7/23/2013 Page 67 of 67

A
SIZE DWG NO SH REV
399A4822 67 B

Device System Settings

VR-31 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR-31E 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR-32 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR-32E 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR-33 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR-33E 0426 RELIEF VALVE
SET 450.0 PSIG OR 3103 KPAG
HYDROSTATIC RELIEF VALVE FOR DISCHARGE PIPING
VR14-1 0419 APU PRESSURE RELIEF VALVE
SET 150.0+-1.000 PSIG OR 1034+-6.895 KPAG
DRYER TOWER RELIEF VALVE
VR14-2 0419 APU PRESSURE RELIEF VALVE
SET 150.0+-1.000 PSIG OR 1034+-6.895 KPAG
DRYER TOWER RELIEF VALVE
VR21-1 0434 MAIN HYDRAULIC OIL SUPPLY PUMP PRESSURE RELIEF VALVE
SET 3025+-100.0 PSIG OR 20857+-689.5 KPAG
VR22-1 0434 AUXILIARY HYDRAULIC OIL SUPPLY PUMP PRESSURE RELIEF VALV
SET 3025+-100.0 PSIG OR 20857+-689.5 KPAG
VR23-2 0434 HYDRAULIC SUPPLY LOW PRESSURE RELIEF VALVE
SET 1815+-25.00 PSIG OR 12514+-172.4 KPAG
VR64-10 0420 COOLING WATER PRESSURE RELIEF VALVE- LO COOLER
SET 150.0+-5.000 PSIG OR 1034+-34.47 KPAG
VR64-9 0420 COOLING WATER PRESSURE RELIEF VALVE- LO COOLER
SET 150.0+-5.000 PSIG OR 1034+-34.47 KPAG
VS4-1 0422 FUEL GAS STOP VALVE
VS4-4 0422 FUEL GAS STOP VALVE
VSR-1 0422 STOP/SPEED RATIO VALVE
SLEW TIME = 0.500 +/- 0.250 SECONDS
90 DEGREES ROTATION MAX. STROKE 6.0 INCHES
HYDRAULIC EFFECTIVE AREA 7.67 IN^2

© COPYRIGHT 2012-2013 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained herein is GE Energy GAS Proprietary
Technical Information that belongs to the General Electric Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no
duplication, or other disclosure, or use whatsoever for any, or all such information except as expressly authorized in writing by the General Electric Company,GE Energy
(USA), LLC and/or its affiliates.

GE CLASS II (INTERNAL NON CRITICAL)

GE Energy GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG NO

DRAWN BALLA, SANKAR

A 399A4822

SHEET
DRAWN DATE 2012-12-11 67 of 67

GE Proprietary Information - Class II (Internal) US EAR - NLR



 


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“This information will be provided
during the course”
 >ZDd^Ͳϵ&Dy^
General Electric Company will not accept any liability whatsoever for the work undertaken on the basis of this document.
This information has been released for training purposes only as a basic troubleshooting guide by GE Power & Water, Energy
Technical Training .
This document is Proprietary & Confidential is not to be copied, or in any way transferred to other organizations without the written
permission of GE

NOTE: These alarms are not specific to any particular gas turbine/generator. Not all alarms may be presented here-in. There are
alrms listed in this document that may not apply to some site specific units. User must confirm applicable alarms and setpoints to
their specific unit as-built control system. Setpoint values, levels and control logic should all be verified at site by construction and
commissioning before the unit is released for commerical operation. This document can then be updated as needed to reflect an
actual "as-built" status. Setpoint values, levels and control logic identified here should not be considered accurate due to the flexible
structure of the TCP control system.

Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d':ϭͺϭͺ>D Z'Dd>dDW'E:KhZE>ηϭ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-GJ1-1A NO 0440
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d':ϭͺϮͺ>D Z'Dd>dDW'E:KhZE>ηϭ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-GJ1-2A NO 0440
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d':Ϯͺϭͺ>D Z'Dd>dDW'E:KhZE>ηϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-GJ2-1A NO 0440
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d':ϮͺϮͺ>D Z'Dd>dDW'E:KhZE>ηϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-GJ2-2A NO 0440
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d:ϭͺϭͺ>D Z'Dd>dDWdhZ:KhZE>ηϭ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-J1-1A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d:ϭͺϮͺ>D Z'Dd>dDWdhZ:KhZE>ηϭ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-J1-2A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d:Ϯͺϭͺ>D Z'Dd>dDWdhZ:KhZE>ηϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-J2-1A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
d:ϮͺϮͺ>D Z'Dd>dDWdhZ:KhZE>ηϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-J2-2A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϭϮͺ>D Z'Dd>dDWd,Zh^dd/sϭϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-12A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϭϰͺ>D Z'Dd>dDWd,Zh^dd/sϭϰ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-14A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϭŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϰͺ>D Z'Dd>dDWd,Zh^dd/sϰ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-4A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϲͺ>D Z'Dd>dDWd,Zh^dd/sϲ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-6A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϳͺ>D Z'Dd>dDWd,Zh^dd/sϳ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-7A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
ddϭͺϴͺ>D Z'Dd>dDWd,Zh^dd/sϴ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TA1-8A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
dd/ϭͺϭϮͺ>D Z'Dd>dDWd,Zh^d/Ed/sϭϮ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TI1-12A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
dd/ϭͺϰͺ>D Z'Dd>dDWd,Zh^d/Ed/sϰ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TI1-4A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

Check if other lube oil and bearing

High bearing temperature temperatures are high. If all others are high,
caused by excess rubbing, there could be lube oil cooling issue. If only
dd/ϭͺϲͺ>D Z'Dd>dDWd,Zh^d/Ed/sϲ,/', bearing wear, hot oil from this device is high it could be a bad T/C, try BT-TI1-6A NO 0415
other source, or bad switching to backup element. If still high,
thermocouple could be a problem w/ bearing. Ensure the
lube oil pressure is within specification.

High bearing temperature Check if other lube oil and bearing temps.
caused by excess rubbing, high. If all others high, could be lube oil
dd/ϭͺϴͺ>D Z'Dd>dDWd,Zh^d/Ed/sϴ,/', bearing wear, hot oil from cooling issue. If only this is high it could be a BT-TI1-8A NO 0415
other source, or bad bad T/C, try switching to backup element. If
thermocouple still high, could be a problem w/ bearing.
DGP Hardware / software
'WͺdZͺ>D 'WdZKh> Refer to the DGP manuals. DGP NO A016
failure.
d''<ͺ>D 'EZdKZ&ZDdDWZdhZ,/', No Information Available

If no cold gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high
concentration and check for high DP on rotor
rotor fan differential, or DT-GSC-7, -8, -
d'^ͺ>D 'E^ddKZEdZdDWZdhZ,/', fan. Also check cooling water. If cooling NO 0440
inadequate cooling water. 9
system OK try reducing VAR's and/or load.
Also, could be caused by
NOTE: turbine will shutdown if at least two
excessive VAR's or load.
RTDs exceed alarm limit.

Loss of power supply,

Dew Point
faulty dew point
Sensor,
sensor/controls module, Check power supplies, re-calibrate/replace
Desiccant,
deterioration of desiccant, dew point sensor/controls module, check
d,z',ͺ>D tWK/EddDWZdhZ,/',>ZD Hydrogen dryer NO 0440
improper operation of desiccant, check process/valve line-up for
skid &
hydrogen dryer skid, operating Hydrogen dryer skid
associated
incorrect line-up of
valves
hydrogen dryer skid valves

Loss of power supply,

Dew Point
faulty dew point
Sensor,
sensor/controls module, Check power supplies, re-calibrate/replace
Desiccant,
deterioration of desiccant, dew point sensor/controls module, check
d,z',,ͺ>D tWK/EddDWZdhZ,/',,/',>ZD Hydrogen cycle NO 0440
improper operation of desiccant, check process/valve line-up for
skid &
hydrogen cycle skid, operating Hydrogen cycle skid
associated
incorrect line-up of
valves
hydrogen cycle skid valves

An error has occurred with Check the exciter to determine the issue and
yϮ<ͺ>ZD yϮ<>ZD/E/d/KE Exciter NO A155
the EX2K resolve.
&Y,Ϯͺ>D ,Ϯ&>KtϮϰ,KhZs'KsϭϬϬϬ^& No Information Available
Clogged fuel strainer,
Replace clogged filter. Verify proper switch
&^W,ͺ>D &h>'^^d/EZ/&&WZ^^,/', pressure switch out of 63FGD-1 NO 0422
operation and calibration.
calibration.
Clogged fuel strainer,
Replace clogged filter. Verify proper switch
&^W,,ͺ>D '^^dZ/EZ/&&WZ^^,/',D/EZY pressure switch out of 63FGD-1 NO 0422
operation and calibration.
calibration.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϮŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required
There is no longer a backup overspeed trip in
Speed probes not getting a
the event the primary overspeed, via VTUR,
speed reading. Probes
fails. Recommend shutdown to troubleshoot.
>ϭϮ,ͺͺ>D WZKdDKh>^W^'E>>K^^;>dͿ may have failed, wiring 77HT-1, -2, -3 NO 0415
Verify speed probe wiring and gap settings.
issue or problem with
Check cards functionality by simulating
board.
frequency.
Turbine will trip. Investigate cause of
Overspeed trip possible overspeed. Did load rejection occur from
after load rejection or if base or very high load ? Was there an
>ϭϮ,ͺ>D >dZ/>KsZ^WdZ/WͲ,W 77NH-1, -2, -3 YES 0415
turbine speed otherwise excursion on the grid ? Verify speed probe
exceeds 110%. wiring and gap settings. Check cards
functionality by simulating frequency.

The speed signals are used as part of the

Speed probes not getting a synchronization check logic, without this logic
speed reading. Probes synchronization cannot occur. Also, loss of
77NH-1, -2, -3,
>ϭϮ,ͺ&>dͺ>D >K^^K&WZKdd/s,W^W^/'E>^ may have failed, wiring these speed probes will cause the backup NO 0415
77HT-1, -2, -3
issue or problem with overspeed trip to not function. Recommend
board. shutdown and troubleshoot problem. Verify
speed probe wiring and gap settings.

Turbine will trip. Investigate cause of

Overspeed trip possible overspeed. Did load rejection occur from
after load rejection or if base or very high load ? Was there an
>ϭϮ,ͺWͺ>D WZKdd/sKZKsZ^WͲdZ/W 77HT-1, -2, -3 YES 0415
turbine speed otherwise excursion on the grid ? Verify speed probe
exceeds 110%. wiring and gap settings. Check cards
functionality by simulating frequency.

Turbine oversped as a
result of generator breaker
opening unexpectedly/per
Reset/re-calibrate/replace overspeed
>ϭϮ,>dͺ>D WZKdd/sKsZ^WK>ddZ/W large load rejection, faulty Overspeed Bolt YES 0
bolt/finger
overspeed bolt/finger,
overspeed bolt out of
calibration
Turbine will trip. Determine cause of loss of
speed signal. Verify speed probe wiring and
77NH-1, 2, 3 speed probes
gap settings. Check cards functionality by
to TTUR not getting a
simulating frequency. CAUTION:: This alarm
speed reading. Probes
>ϭϮ,&ͺ>D KEdZK>^W^/'E>>K^^Ͳ,W is latched until a MASTER RESET is 77NH-1, -2, -3 YES 0415
may have failed, wiring
selected. Also, turning gear will be disabled
issue or problem with
while this alarm is present. Therefore the unit
TTUR board.
will not go on turning gear unless a MASTER
RESET is selected.

Problem with 77NH-1, 2, 3

speed probes into TTUR Turbine will trip. Determine problem with
board. Probes getting false speed probes. Verify speed probe wiring and 77NH-1, -2, -3,
>ϭϮ,&ͺͺ>D KEdZK>^W^/'E>dZKh> YES 0415
reading, wiring issue, gap settings. Check cards functionality by 77HT-1, -2, -3
problem with probes, or simulating frequency.
problem with TTUR board.

Problem with 77HT-1, 2, 3

speed probes into TPRO Turbine will trip. Determine problem with
board. Probes getting false speed probes. Verify speed probe wiring and 77NH-1, -2, -3,
>ϭϮ,&ͺWͺ>D WZKdd/s^W^/'E>dZKh> YES 0415
reading, wiring issue, gap settings. Check cards functionality by 77HT-1, -2, -3
problem with probes, or simulating frequency.
problem with TPRO board.

'ϭWhZ's>sd^d/Z^/>K^>Dd
>ϮϬWsdϭͺ>D No Information Available
^t>D
'ϭWhZ's>sd^d/Z^/KWE>Dd^t
>ϮϬWsdϭKͺ>D No Information Available
>D
'ϭWhZ's>sd^d'^^/>K^>Dd
>ϮϬWsdϮͺ>D No Information Available
^t>D
'ϭWhZ's>sd^d'^^/KWE>Dd^t
>ϮϬWsdϮKͺ>D No Information Available
>D
'ϮWhZ's>sd^d/Z^/>K^>Dd
>ϮϬWsdϯͺ>D No Information Available
^t>D
'ϮWhZ's>sd^d/Z^/KWE>Dd^t
>ϮϬWsdϯKͺ>D No Information Available
>D
'ϮWhZ's>sd^d'^^/>K^>Dd
>ϮϬWsdϰͺ>D No Information Available
^t>D
'ϮWhZ's>sd^d'^^/KWE>Dd^t
>ϮϬWsdϰKͺ>D No Information Available
>D
'ϯWhZ's>sd^d/Z^/>K^>Dd
>ϮϬWsdϱͺ>D No Information Available
^t>D
'ϯWhZ's>sd^d/Z^/KWE>Dd^t
>ϮϬWsdϱKͺ>D No Information Available
>D
'ϯWhZ's>sd^d'^^/>K^>Dd
>ϮϬWsdϲͺ>D No Information Available
^t>D
'ϯWhZ's>sd^d'^^/KWE>Dd^t
>ϮϬWsdϲKͺ>D No Information Available
>D
'ϰWhZ's>sd^d/Z^/>K^>Dd
>ϮϬWsdϳͺ>D No Information Available
^t>D
'ϰWhZ's>sd^d/Z^/KWE>Dd^t
>ϮϬWsdϳKͺ>D No Information Available
>D
'ϰWhZ's>sd^d'^^/>K^>Dd
>ϮϬWsdϴͺ>D No Information Available
^t>D
'ϰWhZ's>sd^d'^^/KWE>Dd^t
>ϮϬWsdϴKͺ>D No Information Available
>D
WhZ's>sd^d&/>Ͳ,/dE>KEd^d
>ϮϬWsd&d^ͺ> No Information Available
^ZE

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Observe lift oil supply press. Gauge reading

63QB-1 is reset (lift oil on outside of lube oil skid. If reading greater
pressure present) even than 2870 psig then 20QB1 is stuck open.
though 20QB-1 is de- Measure across output on card, should be 0 20QB1 , 63QB-
>ϮϬYϭͺ>D /^K>d/KEs>s/EKd>K^ NO 0434
energized, 20QB-1 stuck V, if not then relay stuck, if so then problem 1
open, 63QB-1 not w/ solenoid. If reading less than 2770 psig
functioning correctly then 63QB-1 is defective. Must fix defective
component prior to re-start of turbine.

Fault in the generator,

Isophase Bus Duct, GSU
LPSO relay is only a back-up protection.
Step-up transformer,
There should be a trip from the primary
>Ϯϭͺϳϴͺϭͺ> >W^K>ZD͗/^dEZ>zdZ/W generator breaker and 21/78-A1 NO A016
relays and a thorough investigation of the
percentage of the line
tripping should be conducted.
depending on the setting
required by the customer.

Check oscillographic report to identify

>ϮϭͺϳϴͺϮͺ> >W^K>ZD͗KhdͲK&Ͳ^dWZ>zdZ/W Power swing 21/78-A2 NO A016
problem.
Generator Voltmeter should be checked for
AC power is lost in one or
what phase (s) has (have) no reading (s).
more phases due to blown
>Ϯϭͺϳϴͺϯͺ> >W^K>ZD͗sK>d'dZE^&Z&h^&/> Depending on the severity of the condition of 21/78-A3 NO A016
fuse (s), disconnected wire
the unit, normal shutdown should be
(s), defective PT, etc.
performed.
LPSO relay is not functioning properly which
Defective relay board (s) or
might cause undesirable tripping. Servicing
>Ϯϭͺϳϴ&ͺ>D >W^KZ>zZ/d/>^>&d^d&/>hZ other internal problem with 21/78-FAIL NO A016
of the relay is recommended. Also ref. GEK-
LPSO.
106266 for more details.
Loss of power to LPSO due
to blown power supply LPSO relay is de-activated. Relay checkout
>ϮϭͺϳϴW^ͺ>D >W^KZ>zWKtZ^hWW>z>K^^ 21/78-PS NO A016
fuse(s) or fault in the power must be conducted.
supply circuit.

Generator terminal voltage Reduce terminal voltage immediately until

>Ϯϰyͺs,>D yϮ<'EsK>d^ͬ,Zd,/', Exciter NO A155
too high for existing speed. alarm clears.

Generator terminal voltage Reduce terminal voltage immediately until

>Ϯϰyͺs,d>D yϮ<'EsK>d^ͬ,Zd,/',dZ/W Exciter NO A155
too high for existing speed. alarm clears.

All of the synchronization

check conditions have
been met but the K25A
relay has not been View VPRO diagnostic alarms. Investigate
enabled. Could be a any diagnostics found, verify K25A relay
>ϮϱͺEͺ> <ϮϱZ>z,^EKdEE> K25A relay NO Controller
defective relay, a problem operation and that the connections on TREG
with the TREG board, or and to VPRO are secure.
loose connection between
the TREG and VPRO
boards.
Verify actual temperature to determine if
temperature is in range of switch calibration
One of three atomizing air
dKD//E'/ZdDWZdhZ^t/d, 26AA-1A, -1B, -
>Ϯϲͺ^E^Z per device summary. Verify high temperature
temperature switches is NO 0425
dZKh> 2
reading high. switch calibration. Replace switch if
calibration is correct.
Usually indicates real reading of atomizing air
Two of three atomizing air
temperature high. Check upstream devices 26AA-1A, -1B, -
>Ϯϲ,ͺ>D dKD//E'/ZdDWZdhZ,/', temperature switches are YES 0425
such as atomizing air cooler and isolating 2
reading high.
valve.
Note other alarms on HMI as they may help
Cooling & Sealing air leak, pinpoint problem. Physically verify at least
exhaust fan(s) not running, one 88BT fan is running. Confirm proper
>ϮϲdϮ,ͺ>D dhZ/EKDWZdDEddDWZdhZ,/', defective temperature wiring and calibration of temperature switch. 26BT-2 NO 0436
switch Verify temperature with a second source. If
high temperature verified, should not operate
long in this condition.

>ϮϲZd,,ͺ ,/',Zd&KZWWDDKͲ>K>/D/d No Information Available

>ϮϲZd>,ͺ ,/',Zd&KZ^WWDDKͲ>K>/D/d No Information Available

>ϮϲZdD,ͺ ,/',Zd&KZ^WDDKͲ>K>/D/d No Information Available

>ϮϲZdW,ͺ ,/',Zd&KZ/&&DKͲ>K>/D/d No Information Available

Inside of turbine control Check temperature inside turbine control

Card cold
panel is too warm, possibly panel, verify ventilation ports are not blocked.
>Ϯϲd,ͺ>D KEdZK>WE>dDWZdhZ,/', junction NO Controller
due to PEECC temperature Also check temperature control inside
temperature
being too warm. PEECC is working properly.

NOTE: Overtemperature may trip exciter,

Inside of LEC (LCI-Exciter therefore must cool it down before the Exciter power
Compartment) too warm, temperature high trip. Reduce field current conversion
>Ϯϲyͺ>D yϮ<WKtZKEsDKh>dDW,/', inside of exciter too warm, within 60 seconds until alarm clears. Verify module NO A155
exciter cooling fans not air conditioner is working in LEC. Verify temperature
running. exciter cooling fans are operating. Determine detector
other sources of heating.

Inside of LEC (LCI-Exciter Exciter power

Exciter will trip causing the generator breaker
Compartment) too warm, conversion
to open. This alarm will be preceded by the
>Ϯϲyͺdͺ>D yϮ<WtZKEsZ^/KEDKdDW,/',ͲdZ/W inside of exciter too warm, module NO A155
high power conversion mod temp alarm
exciter cooling fans not temperature
(L26EX_ALM)
running. detector

>ϮϲyϮϭ<ͺ>D yϮϭ<WKtZKEsDKh>dDW,/', No Information Available

yϮϭ<WtZKEsZ^/KEDKdDW,/',Ͳ
>ϮϲyϮϭ<ͺdͺ>D No Information Available
dZ/W

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Distillate Fuel Temperature

is high, temperature switch Check controller on heater at fuel forwarding
>Ϯϲ&ϭ,ͺ>D /^d/>>d&h>dDWZdhZ,/', failure or out of calibration, skid. Check temperature switch operation 26FD-1 NO 0427
possible cooling system and its wiring. Verify switch calibration.
problem.

The combustion reference

temperature (TTRF1) is Ensure the GT will be transferred to subpilot
>Ϯϲ&y/,ͺ>D ͘Z͘d͘,/',&KZWDϭ>KZ:d/KEDK 52GX-1 NO
high during the load premix mode after load rejection.
rejection.

Generator collector cab Verify good air flow into generator collector
inlet air temperature is too cab, check for high DP alarm for collector
>Ϯϲ'Ϯϯͺ>D 'EK>>dKZ/E>ddDWZdhZ,/', DT-GAC-23 NO 0440
warm while generator cab fan which would restrict air flow. Reduce
breaker closed. load. Verify RTD operation and wiring.

Generator collector cab

outlet air temperature is too Verify good air flow into generator collector
warm while generator cab, check for high DP alarm for collector
>Ϯϲ',ϭϳͺ>D 'EK>>dKZKhd>ddDWZdhZ,/', DT-GAH-17 NO 0440
breaker closed. Excess cab fan which would restrict air flow. Reduce
heat being produced inside load. Verify RTD operation and wiring.
collector cab.

Check cooling water system for proper flow

Inadequate cooling to DT-GGC-10, -
>Ϯϲ''ͺ>D 'EZdKZK>'^dDWZdhZ,/', and temperature. Reduce load. Verify RTD NO 0440
generator. 11, -12, -13
operation and wiring.
Check cooling water system for proper flow
Inadequate cooling to DT-GGC-10, -
>Ϯϲ''ͺ>D 'EZdKZK>'^dDWZdhZ,/', and temperature. Reduce load. Verify RTD NO 0440
generator. 11, -12, -13
operation and wiring.
Observe HMI for other RTD alarms, verify
Inadequate H2 circulation
cooling water, check both H2 readings, check DT-GGC-10, -
>Ϯϲ''^ͺ>D 'E,/',K>'^dDWZdhZ^WZ or RTD not reading NO 0440
rotor fan for high DP. If one RTD reading is 11, -12, -13
correctly.
far from others, try using spare RTD element.

One or more RTDs not

reading correctly and
probably disconnected. If
reading is greater than or Observe RTD screen for any anomalies.
equal to 800 °F (427 °C) Observe HMI for other RTD alarms. Verify All generator
>Ϯϲ''&ͺ>D 'EZdKZZdKhdK&>/D/d^ the signal leg is most likely RTD operation and wiring. If one RTD temperature NO 0
disconnected. If reading reading is far from the others try using spare monitor RTDs
less than or equal to -100 RTD element.
°F (-38 °C) the reference
leg is most likely
disconnected.

Observe RTD screen for any anomalies.

One or more RTDs reading
Observe HMI for other RTD alarms. Verify All generator
greater than 800 °F (427
>Ϯϲ''&,ͺ>D 'EZdKZZd,/',&/>hZdd RTD operation and wiring. If one RTD temperature NO 0
°C). Signal leg of RTD most
reading is far from the others try using spare monitor RTDs
likely disconnected.
RTD element.

One or more RTDs reading Observe RTD screen for any anomalies.
less than or equal to -100 Observe HMI for other RTD alarms. Verify All generator
>Ϯϲ''&>ͺ>D 'EZdKZZd>Kt&/>hZdd °F (-38 °C). Reference leg RTD operation and wiring. If one RTD temperature NO 0
of RTD most likely reading is far from the others try using spare monitor RTDs
disconnected. RTD element.

If no cold gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high
>Ϯϲ'',ͺ>D 'EZdKZ,Kd'^dDWZdhZ,/', concentration and check for high DP on rotor 52GX-1 NO 0444
rotor fan differential, or
fan. Also check cooling water. Verify RTD
inadequate cooling water.
operation and wiring. Reduce load.

If no cold gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high DT-GGH-28, -
>Ϯϲ'', 'EZdKZ,Kd'^dDWZdhZ,/', concentration and check for high DP on rotor NO 0440
rotor fan differential, or 29
fan. Also check cooling water. Verify RTD
inadequate cooling water.
operation and wiring. Reduce load.

If no cold gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high DT-GGH-28, -
>Ϯϲ'',ͺ>D 'EZdKZ,Kd'^dDWZdhZ,/', concentration and check for high DP on rotor NO 0440
rotor fan differential, or 29
fan. Also check cooling water. Verify RTD
inadequate cooling water.
operation and wiring. Reduce load.

If no hot gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high
>Ϯϲ''<ͺ>D 'E&ZDKDDKEK>'^dDW,/', concentration and check for high DP on rotor DT-GGK-24 NO 0440
rotor fan differential, or
fan. Also check cooling water. Verify RTD
inadequate cooling water.
operation and wiring. Reduce load.

Generator stator The generator should not be operated when

'EZdKZ^ddKZEdZ;K>>dKZEͿ temperature is excessive the stator temperature is excessive. Check DT-GSA-34, -
>Ϯϲ'^ͺ>D NO 0440
dDW,/', caused by lack of cooling cooling system, reduce overload on the 35, -36
or overload. generator.

If no cold gas high alarm, may have problem

Generator too warm due to
with H2 concentration or circulation. Verify H2
poor H2 circulation, high
concentration and check for high DP on rotor
'EZdKZ^ddKZEdZdDWZdhZ rotor fan differential, or DT-GSC-7, -8, -
>Ϯϲ'^ͺ>D fan. Also check cooling water. If cooling NO 0440
,/', inadequate cooling water. 9
system OK try reducing VAR's and/or load.
Also, could be caused by
NOTE: turbine will shutdown if at least two
excessive VAR's or load.
RTDs exceed alarm limit.

Generator stator The generator should not be operated when

'EZdKZ^ddKZEdZ;dhZEͿdDW temperature is excessive the stator temperature is excessive. Check DT-GSF-31, -
>Ϯϲ'^&ͺ>D NO 0440
,/', caused by lack of cooling cooling system, reduce overload on the 32, -33
or overload. generator.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Water injection skid

temperature is high, Verify the water injection compartment vent
temperature switch failure fan is running. Check temperature switch
>Ϯϲ:^Ϯ,ͺ>D tdZ^</E>K^hZdDWZdhZ,/', 26JS-2 NO 0462
or out of calibration, operation and its wiring. Verify switch
possible cooling system calibration.
problem.

Check for proper operation of the lube oil

Lube oil header heat exchangers, cooling water fans (proper
>ϮϲYͺ>D >hK/>,ZdDWZdhZ,/', 26QA-1 NO 0416
temperature is high. rotation) and temperature regulating valve.
Check the temperature switch operation.

Lube oil heater not working

properly. This could be due
Check HMI screen to see if lube oil heater is
to moisture on heater head
on. If so, verify lube oil temperature on gauge
>ϮϲYEͺ>D >hK/>dE<dDWZdhZ>Kt (side of reservoir) causing LT-OT-3A, -4A NO 0416
on side of reservoir. If indeed < 41 °F
short to ground tripping
troubleshoot heater issue.
MCC, blown starter fuse,
problem with T/C's.

Verify proper operation of the lube oil heat

Lube oil header exchangers, cooling water fans (proper 26QT-1A, -1B,
>ϮϲYdͺ>D dhZ/E>hK/>,ZdDW,/',dZ/W NO 0416
temperature is high. rotation), temperature regulating valve, and 26QA-1
temperature switches.
One of the lube oil header
Check temperature switch operation and its 26QT-1A, -1B,
>ϮϲYdͺ^E^Z dhZ>hK/>,ZdDW^t&h>d temperature switches is NO 0416
wiring. Verify proper switch calibration. 26QA-1
bad.
Water injection skid
temperature is low, Verify the water injection compartment space
temperature switch failure heater is running. Check temperature
>ϮϲtZϮ>ͺ>D tdZ^</E>K^hZdDWZdhZ>Kt 26WR-2 NO 0462
or out of calibration, switch operation and its wiring. Verify switch
possible heating system calibration.
problem.

APU is only used for the filter cleaning

system. Should be fixed if filter cleaning
desired. Will most likely be accompanied by
>ϮϳEͺ>D Wh>K^^K&WKtZ>ZD Loss of power to APU skid. 27AD-1 NO 0419
other APU/air inlet alarms. NOTE: if the filter
is dirty and can't be cleaned the turbine my
shutdown on high inlet filter DP.

This alarm will appear

Troubleshooting while turbine running is not
when the DC power supply
recommended. Measure each side to
drops below 105 VDC.
ground to see which is grounded and Turbine control
Could be a partial ground
>Ϯϳͺ>D WKtZ^hWW>zhEZsK>d'>ZD investigate ground from there. Check the panel voltage NO Controller
on either the +125 VDC or -
voltage on the battery charger and monitor
125 VDC side of the DC
investigate why it is less than 105 VDC.
bus to or in the turbine
Refer to the battery charger manuals.
control panel.

Verify MCC is on and ensure a backup seal

DC supply voltage to the for the generator H2. Check the DC voltage
>Ϯϳ^>ͺ>D DKdKZhEZsK>d'Ͳ^>K/> emergency seal oil is low. level to emergency seal oil pump. Verify 27ES-1 NO 0416
MCC may be turned off. proper operation and wiring of relay. Check
the battery charger DC output.

The is no DC voltage
supply to the fire protection Check for power to the fire protection relay
relay panel located in the located in PEECC. Verify proper operation of
>Ϯϳ&ϭͺ>D &/ZWZKdd/KEdZ/WZ>zhEZsK>d' 27F-1 NO 0426
PEECC. DC breaker may the undervoltage contactor. Turn on
be off in the DC breaker breaker the DC breaker.
panel in PEECC.

This circuit supplies AC

power to several devices Check the power to the MCC 1A bus. Verify
used for unit operation. . proper operation of undervoltage contactor.
>ϮϳDϭEͺ>D WhEZsK>d' 27MC-1A NO 0440
Power to the MCC is Reference PEECC drawings for location and
disconnected or fuse for wiring.
relay is blown.
Check the power to the MCC essential bus.
Power to essential bus is
Verify proper operation of undervoltage
>ϮϳDϭEͺ>D Wh^ϭhEZsK>d' disconnected or fuse is 27MC-1E NO 0440
contactor. Reference PEECC drawings for
blown.
location and wiring.
This circuit supplies AC
power to several devices Check the power to the MCC 1 bus. Verify
used for unit operation. . proper operation of undervoltage contactor.
>ϮϳDϭEͺ>D WhEZsK>d' 27MC-1 NO 0440
Power to the MCC is Reference PEECC drawings for location and
disconnected or fuse for wiring.
relay is blown.

This circuit supplies AC

power to several devices Check the power to the MCC 2 bus. Verify
used for unit operation. . proper operation of undervoltage contactor.
>ϮϳDϮEͺ>D WhEZsK>d' 27MC-2 NO 0440
Power to the MCC is Reference PEECC drawings for location and
disconnected or fuse for wiring.
relay is blown.

Condition will cause a pre-ignition trip. Verify

MCC is on and ensure backup lube oil.
DC voltage supply to the
Check for the DC voltage level to emergency
>ϮϳY>ͺ>D DKdKZhEZsK>d';>hK/>Ϳ emergency lube oil is low. 27QE-1 NO A019
lube oil pump. Verify proper operation and
MCC may be turned off.
wiring of relay. Check the battery charger
DC output. Ensure backup lube oil.

Voltage supply to the water Check the power to the water wash skid.
>Ϯϳtͺ>D tdZt^,^</hEZsK>d' 27WD-1 NO 0461
wash skid is low. Verify proper operation and wiring.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

Flame less than 25% could

be caused by dirty flame
detector, bad connection or
defective turbine control
panel card. Flame seen
when less than 13.5 % Identify which flame detector(s) have low
speed could be caused by intensity. Verify proper operation of the flame Flame
>Ϯϴ&ͺ>D &>DddKZdZKh> NO 0415
intermittent connection, detector system and wiring. Ensure that the Detectors
defective turbine control flame detector window(s) is (are) clean.
panel card. Loss of flame
trip will occur if three read
lower than 15%. Can view
flame intensities on FLAME
HMI screen.

Alarm will only be seen during shutdown.

Flame detector possibly Clean flame detector. Shine light on it and
dirty, bad connection, verify stable signal in controller. If strong
defective turbine control stable signal, then problem could be with Flame
>Ϯϴ&ͺ^ ,DZ&>DKhdhZ/E'^,hdKtE NO 0415
panel card, or chamber combustor. OK to run but monitor and Detectors
blew out prior to 'ramp to contact GE if it occurs consistently after
blowout'. cleaning and checking detect. Check gas
fuel supply pressure.
The most common cause is
Turbine will trip. Do not re-start unit until
running out of fuel or
cause of loss of fuel flow and/or pressure, or
inadequate pressure to
inability to detect flame has been remedied. Flame
>Ϯϴ&dͺ>D >K^^K&&>DdZ/W maintain fuel flow. Could YES 0415
Check for damaged crossfire tubes or Detectors
also be due to flame
combustors. Verify proper control valve
detectors being dirty or
position.
failure.

No or low fuel
Turbine will trip. Do not re-start unit until
pressure/flow during
cause of loss of fuel flow and/or pressure has
startup causing
been remedied. Note that this alarm will
Stop/Speed Ratio Valve 96SR-1, -2,
>Ϯ^&dͺ>D ^dZdhW&h>&>Kty^^/sdZ/W occur if valve is stroked greater than 20% YES 0422
(SRV) to open greater than 90SR-1
during calibration and this is OK. Check SRV
20% to compensate.
servo reference and feedback and verify
Defective servo, or valve
position.
badly out of calibration.

Runback is initiated. Variation in Modified

Wobbe Index could lead to non-critical gas
control valve operation and subsequent flow
Gas Fuel Performance
split inaccuracy which could result in high FTG-1A, -1B, -
>ϯϬͺ&'tͺ>D &h>'^Dt/WZD/y>K/E'>K<Khd heater failure. Loss of gas NO 0422
combustion dynamics and NOx. Confirm 2A
fuel thermocouples.
proper operation of gas fuel performance
heater. Verify wiring and operation of gas
fuel thermocouples.
Example of possible causes could be sticking
valve or limit switch not making on demand of
The atomizing air valve is
valve. Visual inspection should verify
not opening when it was
position of valve with respect to demand
>ϯϬϭW^ͺ>D hW^dZD,/Ͱ>KWK^/d/KE&h>d asked to open or not 20AA-1 NO 0425
open or close. Check the motorized valve
closing when it was asked
operation by forcing the valve close and
to close.
open commands. Verify limit switches
operation and wiring.
Example of possible causes could be sticking
valve or limit switch not making on demand of
The atomizing air valve is
valve. Visual inspection should verify
not opening when it was
position of valve with respect to demand
>ϯϬϮW^ͺ>D KtE^dZD,/Ͱ>KWK^/d/KE&h>d asked to open or not 20AA-2 NO 0425
open or close. Check the motorized valve
closing when it was asked
operation by forcing the valve close and
to close.
open commands. Verify limit switches
operation and wiring.
Example of possible causes could be sticking
valve or limit switch not making on demand of
The atomizing air valve is
valve. Visual inspection should verify
not opening when it was
position of valve with respect to demand
>ϯϬϱW^ͺ>D KtE^dZD,/ͰDWK^/d/KE&h>d asked to open or not 20AA-5 NO 0425
open or close. Check the motorized valve
closing when it was asked
operation by forcing the valve close and
to close.
open commands. Verify limit switches
operation and wiring.
Examine readings from controls software to
determine which of the transducers readings
is different. Possible causes could be tubing
Fault detected in AA
leaks, valve misalignment or device 63AD-1A, -1B, -
>ϯϬWͺ&>d /&&ZEd/>WZ^^dZE^hZ&h>d Pressure Ratio NO 0425
calibration. Check the calibration of the three 1C
Transducers.
atomizing air differential pressure
transmitters. Verify the card's functionality by
simulating the 4 - 20 ma input.

This alarm is tied to the

three atomizing air valves
each having 2 limit
switches . After the valve
has traveled to full stroke Possible Causes are: Faulty Limit Switch,
(open or close) determined Bad wiring, limit switch not adjusted properly
>ϯϬ&ͺ>D ϮϬWK^/d/KE&<&h>d 20AA-1, -2, -5 NO 0425
by a time constant, this for valve position, sticking valve or power
alarm provides an switch to valves is off.
indication that the open
and close limit switches are
not following proper
position at valve full stroke.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

The ratio of absolute

atomizing air compressor
Physically check running status of atomizing
pressure to absolute
air compressor. Check for possible
compressor discharge
malfunction of atomizing air compressor (i.e.:
pressure indicates
coupling). Check for proper manual valve
improper output of the
>ϯϬWZ> WZ^^Zd/K>Kt>/D/dͬKDWZKE alignment. Ensure power is on to 20AA 20AA-1, -2, -5 NO 0425
atomizing air compressor.
valves. Check proper position of 20AA
Several scenarios are
valves so that the valve alignment coincides
possible with the
with current running status of GT. Verify
compressor on and various
calibration of atomizing air DP transmitters.
positions of 20AA-5 and
20AA-2.

The ratio of absolute

atomizing air compressor
Physically check running status of atomizing
pressure to absolute
air compressor. Check for possible
compressor discharge
malfunction of atomizing air compressor (i.e.:
pressure indicates
coupling). Check for proper manual valve
improper output of the
>ϯϬWZ>> WZ^^hZZd/K>Kt>KtZ>/D/d alignment. Ensure power is on to 20AA 20AA-1, -2, -5 NO 0425
atomizing air compressor.
valves. Check proper position of 20AA
Several scenarios are
valves so that the valve alignment coincides
possible with the
with current running status of GT. Verify
compressor on and various
calibration of atomizing air DP transmitters.
positions of 20AA-5 and
20AA-2.

The difference between

Verify the calibration of evaporative cooler
tdZKEhd/s/dzZ/E'^ evaporative cooler system
>ϯϬͺ>D system sump conductivity transmitters and 96AC-22, -23 NO 0471
D/^Dd, sump conductivity
their wiring.
transmitters is very high.

The evaporative cooler Check the calibration of the evaporative

>ϯϬ&ͺ>D tdZKEhd/s/dz/E^dZhDEd&/> system sump conductivity cooler system sump conductivity transmitters 96AC-22, -23 NO 0471
transmitter has failed. and their wiring.

The evaporative cooler

Investigate the cause for high conductivity
>ϯϬ,ͺ>D tdZKEhd/s/dzy^^/s>z,/', system sump conductivity 96AC-22, -23 NO 0471
and check the calibration of the transmitters.
is very high.

The evaporative cooler

Investigate why the sump water level is high
>ϯϬ,,ͺ>D ,/',tdZ>s>Ͳ/DD/E^WZY system sump water level is 96AC-21 NO 0471
and resolve.
very high.

The IGV angle is

/'sE'>EZD/E&KZsWKK>Z approaching the minimum Disable evaporative coolers or increase load
>ϯϬ/'sͺ>D 96TV-1, -2 NO 0469
KWZd/KE IGV angle for evaporative resulting in increased IGV angle.
operation.
The evaporative cooler
Check the calibration of the evaporative
>ϯϬ>&ͺ>D tdZ>s>/E^dZ&/>Ͳ/DDddEZY water level transmitter has 96AC-21 NO 0471
cooler water level transmitter and its wiring.
failed.
The evaporative cooler Investigate why the sump level is low and
>ϯϬ>>ͺ>D sWKK>Z>KttdZ>s> system sump water level is resolve. Makeup the sump water. Check 96AC-21 NO 0471
low. water level transmitter calibration and wiring.
The evaporative cooler
Investigate why the sump water level is high
>ϯϬd,ͺ>D sWKK>ZtdZ>s>/E/E>d,/', system sump water level is 96AC-21 NO 0471
and resolve.
high.
The evaporative cooler
Investigate why the sump water level is high
>ϯϬd,,ͺ>D sWKK>ZtdZ>s>/E/E>d,/',Ͳ,/', system sump water level is 96AC-21 NO 0471
and resolve.
very high.

Check operation and wiring of compressor

The compressor inlet
inlet temperature thermocouples. Wait until
KDW/E>ddDW>KtͲsWKK>Z temperature is too low for CT-IF-1A, -1B, -
>ϯϬdDWͺ>D compressor inlet temperature has increased NO 0471
/^> evaporative cooler 2A
above the minimum required for evaporative
operation.
cooler operation to request system operation.

The evaporative cooler

drain shutoff valve is not
open when the system Verify valve position, valve operation and
>ϯϬsͺ>D sWKK>ZZ/Es>s>K^ 33AC-1 NO 0471
operation has been calibration.
requested. Valve may be
stuck.

The evaporative cooler

drain valve is open when Verify valve position, valve operation and
>ϯϬsKͺ>D sWKK>ZZ/Es>sKWE 33AC-1 NO 0471
the system has been calibration.
turned off.

One or more transmitters

dhZ/E/E>dWZ^^hZdZE^hZ^ Verify proper transmitter operation and 96AP-1A, -1B, -
>ϯϬ&Wͺ^E^Z out of calibration or NO 0492
/^'Z calibration. 1C
possible wiring issue.

>ϯϬ&,ͺ>D WKtZ^z^dD&ZYhEz,/', No Information Available

>ϯϬ&>ͺ>D WKtZ^z^dD&ZYhEz>Kt No Information Available

One or more transmitters

y,h^dhdWZ^^hZdZ^hZ^ Verify proper transmitter operation and 96AP-1A, -1B, -
>ϯϬ&WWͺ^E^Z out of calibration or NO 0492
/^'Z calibration. 1C
possible wiring issue.

The stop valve limit switch

does not indicate that the
valve is in the correct Check the steam injection stop valve for
>ϯϬ:ϭͺ>D ^dD/E:d/KEh'^dKWs>s&h>d>K< commanded position. The proper operation. Verify valve and limit 20AJ-1, 33AJ-1 YES 0431
stop valve is faulty. The switch proper operation and wiring.
limit switch is out of
calibration.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

The auxiliary power unit

>ϯϬWϭͺ>D WhdZKh>>ZD Check APU power supply and wiring. 30AP-1 NO 0419
indicates there is a fault.

The batter charger (located

Check the DC output voltage output from the
in the PEECC) has trouble.
battery charger and AC/DC inputs to battery 30BC-1 and
>ϯϬϭEͺ>D ddZz,Z'ZηϭdZKh> Battery charger turned off. NO 0440
charger. Refer to vendor manuals for further 27MC-1.
Breaker on MCC to battery
troubleshooting.
charger # 1 is off.

The batter charger (located

Check the DC output voltage output from the
in the PEECC) has trouble.
battery charger and AC/DC inputs to battery 30BC-2 and
>ϯϬϮEͺ>D ddZz,Z'ZηϮdZKh> Battery charger turned off. NO 0440
charger. Refer to vendor manuals fro further 27MC-2
Breaker on MCC to battery
troubleshooting.
charger # 2 is off.

Check all gap settings are within specification

There is fault from the from the Bently Nevada panel. Check any Bently Nevada
>ϯϬEͺ&ͺ>D Ed>zEsDKE/dKZ&h>d NO 0
Bently Nevada system. system error messages from the panel. system
Refer to manual.

Check all gap settings are within specification

There is fault from the from the Bently Nevada panel. Check any Bently Nevada
>ϯϬE&^dͺ>D Ed>zEs^z^dD&h>d^dZd/E,//d NO 0
Bently Nevada system. system error messages from the panel. system
Refer to manual.

Check if other lube oil and bearing

High bearing temperature
temperatures are high. If all others high,
caused by excess rubbing, All bearing
could be lube oil cooling issue. If only this is
>ϯϬdͺ>D Z/E'Dd>dDWZdhZ,/', bearing wear or hot oil from metal NO 0
high it could be a bad T/C, try switching to
other source. Possibly a thermocouples
backup element. If still high, could be a
bad thermocouple.
problem w/ bearing.

Unit will trip. Fan not Ensure fan operates when turned on, check
running, pressure switch calibration on pressure switch and that
>ϯϬd&>d dhZ/EKDWd>K^^K&sEd/>d/KEdZ/W out of calibration, or ambient port is clear. Ensure turbine 63AT-1, -2 YES 0436
ambient port on switch compartment door is closed. Verify MCC is
clogged. on.

The compressor bleed

Verify the compressor bleed valve positions
valve open and close limit 33CB-1, -2, -3, -
and identify which limit switch (open or close)
>ϯϬͺ& KDWZ^^KZ>s>s&<&h>d switches are showing open 4, -5, -6, -7, -8, YES 0417
is faulty. Verify the open and close limit
and close indications at the 20CB-1, -2
switches functionality and their wiring.
same time.
Verify valve position. Shutdown and repair
Bleed valve could be stuck, recommended. Will still be allowed to
CPD air not getting to operate but not recommended if valve is not
valve, solenoids not firing closed. Turbine may trip when breaker is 33CB-1, -2,
>ϯϬͺ>D KDWZ^^KZ>s>s&/>hZdKKWE NO 0417
or are jammed, failure opened if limit switch indicating closed 20CB-1
inside bleed valve. Failure instead of open or if valve jams. Turbine
of valve limit switch. cannot be re-started until all valves indicate
correct position.
s>K^&h>dͲZhE<dK^W/EE/E'
>ϯϬs&>d No Information Available
Z^Zs

Caused by any
combination of: Check tank pressure and that panel is
1. Low pressure in tank powered on. Check ball valve/limit switch in
2. Fire protection panel off pilot control cabinet. Should be valved in
>ϯϬϭͺ>D &/ZWZKdd/KE^z^dDdZKh> 3. Ball valve/limit switch in service position. In main control cabinet 30CC-1 NO 0426
pilot control cabinet closed observe error codes on the three zone
4. Fault detected by system control boards. Refer to fire protection
(I.e. ground fault most system manuals.
common)

Caused by any
combination of: Check tank pressure and that panel is
1. Low pressure in tank powered on. Check ball valve/limit switch in
2. Fire protection panel off pilot control cabinet. Should be valved in
>ϯϬϮͺ>D &/ZWZKdd/KE^z^dDdZKh> 3. Ball valve/limit switch in service position. In main control cabinet 30CC-2 NO 0426
pilot control cabinet closed observe error codes on the three zone
4. Fault detected by system control boards. Refer to fire protection
(I.e. ground fault most system manuals.
common)

Unit failed to go on cool

down, or the cool down
The turning gear will trip and a master reset
cycle was aborted prior to
is required before trying again. Ensure
cool down timer timeout.
>ϯϬ dhZE/E''ZhE>dKZKdd^,&d turning gear MCC is on, fuse is good, and 77HT-1, -2, -3 YES 0415
Turning gear MCC may be
lube oil heater MCC is on. Also verify lube oil
off or starter fuse may be
temp is > 70 °F (21 °C).
blown. Oil may be too cold
causing excess friction.

The steam injection aft

control valve limit switch
does not indicate that the Check the steam injection aft control valve
20CJ-2, 33CJ-
>ϯϬ:Ϯͺ>D WKtZh'&dEdZ>s>sWK^/d/KE&h>d valve is in the correct for proper operation. Verify valve and limit YES 0431
2
commanded position. The switch proper operation and wiring.
valve is faulty. The limit
switch is out of calibration.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

No heartbeat detected
between turbine controller
Communication
and Exciter or
link between
communication link Address communication problem, check all
>ϯϬKDͺy&>d y/dZdKD<s/KDDhE/d/KE&h>d turbine NO A155
between controller and communication connections and switches.
controller and
exciter is not healthy due to
Exciter
disconnect or
communications problem.

No heartbeat detected
between turbine controller Communication
NOTE: Turbine cannot be started with this
and LCI or communication link between
fault. Also could cause a starting means trip if
>ϯϬKDͺ>ϭ&>d '>/E<dKd,>^ϮϭϬϬ&h>d link between controller and turbine NO A140
alarm occurs during start. Once above 90%
exciter is not healthy due to controller and
speed this alarm is irrelevant.
disconnect or L1
communications problem.

No heartbeat detected
between turbine controller Communication
NOTE: Turbine cannot be started with this
and LCI or communication link between
fault. Also could cause a starting means trip if
>ϯϬKDͺ>Ϯ&>d '>/E<dKd,>^ϮϭϬϬ&h>d link between controller and turbine NO A140
alarm occurs during start. Once above 90%
exciter is not healthy due to controller and
speed this alarm is irrelevant.
disconnect or L2
communications problem.

No heartbeat detected
between turbine controller Communication
NOTE: Turbine cannot be started with this
and LCI or communication link between
fault. Also could cause a starting means trip if
>ϯϬKDͺ^^&>d '>/E<dKd,>/&h>d link between controller and turbine NO A140
alarm occurs during start. Once above 90%
exciter is not healthy due to controller and
speed this alarm is irrelevant.
disconnect or LCI
communications problem.

A problem with the IONet

Determine the faulty IO pack and investigate NO but
and at least one of the IO
Toolbox diagnostic alarms. If the alarm need to
packs on one of the cores Any IO pack on
>ϯϬKDDͺ>D KDDhE/d/KE^&/>t/d,Ez/KW< persists it should be investigated. If this do Controller
has been detected. Check any core
cannot be easily determined or resolved DIAG
toolbox for diagnostic
contact GE. RESET
alarms.

Most commonly due to

Turbine will trip. Determine cause of CPD
CPD transmitter isolation
>KtKDWZ^^KZ/^,Z'WZ^^hZͲ transmitters not sensing pressure. Ensure all 96CD-1A, -1B, -
>ϯϬWͺ> valves not opened after YES 0417
hE/d^,hdKtE transmitters valved in and wiring is OK, verify 1C
waterwash or sense lines
calibration.
blocked.

The compressor pressure

discharge measurement is
constant when it is Unit will initiate a fired shutdown. Ensure
96CD-1A, -1B, -
>ϯϬWͺZKͺ& WZdK&,E'&h>dͲ^,hdKtE expected to vary. Issue transmitters are operating correctly. Refresh NO 0417
1C
with the transmitters, the downloaded IO configuration.
calibration, wiring, or
communication.

The compressor discharge

pressure has exceeded the Recalibrate the three pressure transducers. 96CD-1A, -1B, -
>ϯϬW> WKhdK&>/Zd/KE NO 0417
allowed limit when the Verify proper wiring and device operation. 1C
turbine is near zero speed.

At least one of the

Verify that the processors are in the
controllers is not in Controller
Controlling state. Check for disconnected
>ϯϬ^ͺdZ>ͺ>D KEdZK>>ZKhdK&KEdZK>>/E'^dd Controlling State and not Communication NO Controller
IONet cables or malfunctioning switches.
communicating properly Links
Rebuild and download application.
with the other controllers.

At least one of the

Verify that the processors are in the
controllers is not producing Controller
Controlling state. Check for disconnected
>ϯϬ^,ͺYͺ>D KEdZK>>Z,Zdd^dKWW the required heartbeat and Communication NO A140
IONet cables or malfunctioning switches.
therefore not Links
Rebuild and download application.
communicating properly.

Turbine will not trip. Compressor will be

protected via compressor operating limit
96CD-1A, -1B, -
>ϯϬ^hZ' KDWZ^^KZ^d>>dd Possible compressor stall. protection. Verify CPD transducers are YES 0417
1C
working properly. Verify proper IGV
operation. If problem persists, contact GE.

Turbine will not trip but condition may result in

Could indicate an anomaly
combustion reference temperature variation.
with compressor flow or a
>ϯϬdͺ&>d KDWZ^^KZ/^,Z'dD/E&h>d Verify T/C's with T/C simulator. If T/C's are CT-DA-1, -2, -3 NO 0415
bad compressor discharge
OK will need to investigate cause of high
temperature (CTD) T/C.
spreads. Contact GE.

Faulty thermocouple, wiring

problem with
thermocouple,
Probably OK if alarm only occurs for short
thermocouple not in well
time during loading/unloading. If sustained
correctly, thermocouple CT-IF-1A, -1B, -
>ϯϬd/&ͺ&>d KDWZ^^KZ/E>ddD/E&h>d then investigate. Test thermocouples and NO 0415
otherwise damaged. May 2A
verify wiring. Try switching to spare element if
see this alarm occasionally
available.
while loading for short time
but clears as air flow
stabilizes.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required
y^^/sdhZ/EKDWdsEd/>d/KEͲ
>ϯϬs&>d No Information Available
,'^WZKdd/KEKDWZKD/^
The CPU temperature is Check that the cooling fan is functioning Controller CPU
>ϯϬͺdZ>ͺKd KEdZK>>ZKsZdDWZdhZ greater than the allowed properly also verify that the CPU is not and NO Controller
limit. overheating. Motherboard
The exciter failed to start Generator
Confirm generator breaker and exciter
>ϯϬyyͺ>D y/dZ&/>ͲKZd/E'>K^hZ after the dead bus closure Breaker, NO A155
operation. Verify proper device wiring.
was confirmed. Exciter

>ϯϬ'Wͺ& 'EWZKd&/>Ͳ^,hdKtEd/DZ/E/d/d No Information Available

Occurs 10 minutes after

Turbine is being shutdown. No operator
>ϯϬ'Wͺ^ 'EWZKd&/>hZ^,hdKtE/E/d/d the preceding L30DGP_CD 74CR-1 NO 0
intervention is possible.
alarm has been initiated.

>ϯϬ/'ͺdZ>ͺZ фZхKEdZK>>Z/'EK^d/>ZD No Information Available

>ϯϬ/'ͺdZ>ͺ^ ф^хKEdZK>>Z/'EK^d/>ZD No Information Available

>ϯϬ/'ͺdZ>ͺd фdхKEdZK>>Z/'EK^d/>ZD No Information Available

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϭ W/ηϭ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 1.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺZ фZхW/ηϭ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 1 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺ^ ф^хW/ηϭ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 1 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺd фdхW/ηϭ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 1 of <T>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/Ϯ W/ηϮ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 2.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϮͺZ фZхW/ηϮ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 2 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/Ϯͺ^ ф^хW/ηϮ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 2 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/Ϯͺd фdхW/ηϮ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 2 of <T>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϯ W/ηϯ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 3.
and terminal boards.

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 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺZ фZхW/ηϯ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 3 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺ^ ф^хW/ηϯ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 3 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺd фdхW/ηϯ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 3 of <T>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϰ W/ηϰ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 4.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺZ фZхW/ηϰ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 4 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺ^ ф^хW/ηϰ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 4 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺd фdхW/ηϰ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 4 of <T>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϱ W/ηϱ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 5.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺZ фZхW/ηϱ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 5 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺ^ ф^хW/ηϱ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 5 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺd фdхW/ηϱ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 5 of <T>
connections between PAIC
core.
and terminal boards.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϭϮŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϲ W/ηϲ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 6.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺZ фZхW/ηϲ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 6 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺ^ ф^хW/ηϲ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 6 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺd фdхW/ηϲ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 6 of <T>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϳ W/ηϳ/'EK^d/>ZD PAIC or terminal board, diagnostic STIC Controller
verify all connections from PAIC to terminal
loose or broken alarm on PAIC RESET
boards.
connections between PAIC board 7.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϳͺZ фZхW/ηϳ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 7 of <R>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϳͺ^ ф^хW/ηϳ/'EK^d/>ZD PAIC or terminal board, STIC Controller
verify all connections from PAIC to terminal alarm on PAIC
loose or broken RESET
boards. board 7 of <S>
connections between PAIC
core.
and terminal boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺWϭ Wηϭ/'EK^d/>ZD PCAA or terminal board, diagnostic STIC Controller
verify all connections from PCAA to terminal
loose or broken alarm on PCAA RESET
boards.
connections between board 1.
PCAA and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺWϭͺZ фZхWηϭ/'EK^d/>ZD PCAA or terminal board, STIC Controller
verify all connections from PCAA to terminal alarm on PCAA
loose or broken RESET
boards. board 1 of <R>
connections between
core.
PCAA and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺWϭͺ^ ф^хWηϭ/'EK^d/>ZD PCAA or terminal board, STIC Controller
verify all connections from PCAA to terminal alarm on PCAA
loose or broken RESET
boards. board 1 of <S>
connections between
core.
PCAA and terminal boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺWϭͺd фdхWηϭ/'EK^d/>ZD PCAA or terminal board, STIC Controller
verify all connections from PCAA to terminal alarm on PCAA
loose or broken RESET
boards. board 1 of <T>
connections between
core.
PCAA and terminal boards.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϭϯŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϭ W/ηϭ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 1.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺZ фZхW/ηϭ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 1 of <R>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺ^ ф^хW/ηϭ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 1 of <S>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϭͺd фdхW/ηϭ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 1 of <T>
between PDIA and terminal
core.
boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/Ϯ W/ηϮ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 2.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϮͺZ фZхW/ηϮ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 2 of <R>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/Ϯͺ^ ф^хW/ηϮ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 2 of <S>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/Ϯͺd фdхW/ηϮ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 2 of <T>
between PDIA and terminal
core.
boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϯ W/ηϯ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 3.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺZ фZхW/ηϯ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 3 of <R>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺ^ ф^хW/ηϯ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 3 of <S>
between PDIA and terminal
core.
boards.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϭϰŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϯͺd фdхW/ηϯ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 3 of <T>
between PDIA and terminal
core.
boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϰ W/ηϰ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 4.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺZ фZхW/ηϰ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 4 of <R>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺ^ ф^хW/ηϰ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 4 of <S>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϰͺd фdхW/ηϰ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 4 of <T>
between PDIA and terminal
core.
boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϱ W/ηϱ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 5.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺZ фZхW/ηϱ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 5 of <R>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺ^ ф^хW/ηϱ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 5 of <S>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϱͺd фdхW/ηϱ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 5 of <T>
between PDIA and terminal
core.
boards.

See Toolbox for actual

alarm. Analog input out of Internally
May be an intermittent condition. Determine
range, other failure of PDIA generated DIAGNO
alarm from Toolbox and troubleshoot. Also
>ϯϬ/'ͺW/ϲ W/ηϲ/'EK^d/>ZD or terminal board, loose or diagnostic STIC Controller
verify all connections from PDIA to terminal
broken connections alarm on PDIA RESET
boards.
between PDIA and terminal board 6.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺZ фZхW/ηϲ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 6 of <R>
between PDIA and terminal
core.
boards.

ůĂƌŵĂƚĂďĂƐĞͲϵ&EŽŶ^ŝƚĞ^ƉĞĐŝĨŝĐ͘džůƐdž ϭϱŽĨϳϴ
 Master
Associated
Signal Name Alarm Description Possible Causes Recommended Course of Action Reset System
Hardware
Required

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺ^ ф^хW/ηϲ/'EK^d/>ZD or terminal board, loose or STIC Controller
verify all connections from PDIA to terminal alarm on PDIA
broken connections RESET
boards. board 6 of <S>
between PDIA and terminal
core.
boards.

See Toolbox for actual

Internally
alarm. Analog input out of
May be an intermittent condition. Determine generated
range, other failure of PDIA DIAGNO
alarm from Toolbox and troubleshoot. Also diagnostic
>ϯϬ/'ͺW/ϲͺd фdхW/ηϲ/'EK^d/>ZD or terminal board, loose or