QURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION _ Note: The gas turbine may be restarted during DAIS operation, unless the lockout described below is in effect. [othe downer aiay ive a : = This region | this region |] This region |}-} andbeyord reqinesno | | J cequiresé |}/] requires10 ||| requires 12 als hrsof DAS |] hrsofoas |}'] hrsof DAS. eperation || operation Time Se & = Caution Note: In the event that the compressor does not operate as required, following ‘shutdown, a lockout period of 20.25 hours will be implemented after shutdown for restart (unit can restart within the first 1.75 hours following shutdown). This is included in the control logic. There will also is a Sub-loop Controller (SLC) in the logic to allow the lockout to be overridden. This will allow a warm restart with a WARNING that “over- riding the lockout could result in performance losses". Lockout period is shown in the figure below: owestsiting wig ae [ai i i i [ a ey [ ERT SS) t spo Toon, Also, if the unit drops down to 3 RPM during any period of the DAIS operation, the lock- out period (shown above) applies. If the rotor speed is at 3 RPM, maintain operation of the DAIS during the entire duration of 3 RPM and then continue DAIS operation once the unit Is back to 120 RPM; however, the lockout period of 20.25 hours does still apply as a result of 3 RPM operation. If the rotor speed drops down to zero for any period of time, the DAIS system should not operate. Pages of aa FOR TRAINING ONLY 12 Turbine alrdoc ‘Slomens Confidential informationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION ‘To prevent this potential blade tip loss, the Direct Air Injection System Is installed. DESCRIPTION ‘The Gas turbine Direct Air Injection System is made up of the following major components: * 150 HP Ingersoll-Rand Air Compressor System that is part of starlup/shutdown instrument air system. +. Air Filter with Remote Differential Pressure Indication Switch. + Two-inch Regulating Valve ~ Set to 60 PSIG. * Two-Inch Pneumatic Isotation Valve + Nozzles to connect to Borescope ports at Disc Cavity 3 and Disc Cavity 4 2 Sa Soe wt a, at eee anne REPS a ons Mowe rece nae maa Linen oot fr orvenvnt a JN. a ‘yams 150 yp ios Aces Direct Air Injection System The Direct Air Injection System will flow 195 SCFM of 60 PSIG air from the instrument air receiver to the disc cavities 3 and 4. Operation of the system requires the use of the. startup/shutdown air compressor. ‘The connection of the Direct Air Injection System to the Air Receiver will be a separate line from the Gas Turbine Instrument Air Supply. The supply line will have a manual isolation leading to a particulate filter (MBHS5GATO03). The specifications for this filter are unknown at this time, ‘The filter will have an installed differential pressure switch (MBHS8CP089). The setpoint for this pressure switch is not known at this time. The ‘switch is used for high differential pressure indication at the DCS, indicating the need to change the filter media, Pago i2 of 34 FOR TRAINING ONLY 12 Turbine alrdoc ‘Slomens Confident InformationQURAYYAH IPP PROJECT « GAS TURBINE FAMILIARIZATION third filter, the after filter, which removes any residual traces of desiccant that become entrained in the air as it passes through the air dryer. Instrument Air Header Pressurized air is continuously supplied from the instrument air header for operation of the following system components: + Lube oll package louvers + HP bleed valve + LP bleed valve + Exhaust tunnel conduit cooling © RACstertup bypass + RAC filter drain valve + Turbine disc cavity 2 & 3 temperature control valves, * Startup purge isolation valve 1 & 2 ‘© Startup purge vent valve Shutdown purge valve + Fuel oil overspeed trip valve Fuel gas overspeed trip and main vent valves + Fuel gas manifold continuous purge isolation valves 1 & 2 + Fuel gas manifold purge vent valve + Fuel oil vent & drain valve Direct Air Injection System FUNCTION The Gas Turbine Direct Air Injection System (DAIS) Is used to evenly cool the turbine ‘elements after shutdown. This is accomplished by blowing a steady stream of air into Disc Cavity 3 and Disc Cavity 4, Page 20 of 34 FOR TRAINING ONLY 42 Turbine airoo Slemens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION ‘When the gas turbine is not operating, an auxiliary air compressor and receiver tank supply the required air until system pressure can be maintained by the running gas turbine. Startup/Shutdown Instrument Air Compressor The compressor is 150 HP,, 2 stage reciprocating air compressor that will cycle on and off the maintain the receiver air pressure. ‘When turbine-cooling air is utilized as instrument air, a pressure control valve reduces the turbine cooling air pressure from approximately 12.8 bar to the instrument air operating pressure of 7.24 bar. A separate pressure control valve reduces the auxiliary air pressure from 10.34 bar to the instrument air header pressure of 6.55 bar. ‘An accumulator installed in the instrument air header dampen system pressure surges. In addition to the local indication of pressures and temperatures, the control system will display an instrument air system low-pressure alarm when system pressure drops to 80 psig. A single "trouble" alarm will annunciale on the control system if an auxiliary air compressor malfunction was to occur. The system relief valve is set for 8.62 bar. Pressure Control Valves: When turbine rotor cooling air Is utilized as the instrument alr source, a pressure control valve reduces the cooling air pressure to an instrument air operating pressure of 7.24 bar. A separate pressure control valve reduces the receiver Pages of 4 FOR TRAINING ONLY 42 Turbine aloe ‘Slemens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION Components Air Compressor: 15 hp, 3 stage air compressor with an inner and after cooler. The compressor is equipped with a complete staring unloading system. This automatically relives pressure from cylinders, intercooler and the aftercooler, in addition to draining condensate from traps , when’ the compressor stops. serpents as o2 1ST & 2ND STAGE INTERCOOLER RELIEF VALVES [NR INLET FILTER 16420 PANEL High Load Air Compressor Air Receiver: Capacity of 2271 liters at a pressure of 69 bar. Pressure Regulator Valve: Will maintain a constant alr supply pressure of 2,76 bar psig above shell pressure to the gas manifolds during purging. This is a piloted regulating valve. Purge Isolation Valve: When open, along with Stage Isolation Valves, will allow purge air flow from the receiver tank to the gas manifolds during purging. This is a Fail Closed, pneumatically actuated, on-off ball valve. Pago 26 of 84 FOR TRAINING ONLY 12 Turbine sie.doe ‘lemons Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION provide sufficient discharge pressure to ensure adequate air flow through the pilot nozzles. The Startup/Shutdown Purge System functions to maintain the required air flow during these periods below 2150 rpm as the turbine is accelerating or decelerating, Continuous Manifold Purge (Operation on Fuel Oil) Immediately after transfer from natural gas to fuel oll and during operation on fuel oil, air from the combustor shell is continuously provided to the fuel gas manifold (pilot stage) to prevent recirculation of hot combustion gases through the manifold and to minimize the effects of thermel stress on the fuel nozzle tips. The air passes through two pheumaticelly operated air to opervfall closed ball-lype purge isolation valves. A pneumatically operated air to close/fail open ball-type purge vent valve is installed ina double-block-and-bleed arrangement between the two isolation valves. The piping is monitored by a dual element pressure switch to detect failure of the vent valve and either of the two isolation valves. This pressure switch provides a trip signal to the gas turbine If pressure is sensed in the line between the fuel gas manifold purge isolation valves during operation on fuel gas. A pressure between these isolation valves would indicate either fuel gas leakage or hot combustor shell air leakage into this space. When the fuel gas purge isolation valves are open, the purge vent valve is closed. Purge Air System Diagram Pago 24 of 34 FOR TRAINING ONLY 12 Turbine atrdos ‘Slomens Confidenta! InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION A portion of the cooling air is diverted from the first, second, and third stage blade serrations to blade holes to pass through the blades and exit out the tips into the hot gas path reducing blade temperature. Air exiting the blade tips cools the interstage seals, and is then swept info the hot gas path and into the turbine exhaust. Rotor Cooling Cooling the turbine rotor to maintain a reasonable operating temperature ensures a longer service life. Rotor cooling air exits the rotor cooling air filter and is internally piped to the torque tube seal housing. From the torque tube seal housing, the air is distributed for cooling the turbine intemals outside of the hot gas path. Some of the cooling air is directed through the seal disk assembly to cool the seals and prevent hot gases from escaping along the rotor towards the compressor. Some of the cooling air flows through the torque tube and through the holes in the disc extender into the center core of the rotor. This air cools the rotor disos and disc cavities by flowing between the discs and through the curvic couplings into the disc cavily areas. Direct cooling occurs at the turbine blade root sefrations on all four slages. Effectively this cooling provides a thermal boundary between the blade exposed to the gas path temperature and the turbine discs. A portion of the cooling ait is diverted from the first, second, and third stage blade serrations to blade holes to pass through the blades and exit out the tips into the hot gas path reducing blade temperature. Air exiting the blade tips cools the interstage seals, and is then swept into the hot gas path and to the turbine exhaust. Page of 34 FOR TRAINING ONLY 12 Turbine alrdoe ‘Slomons Confldentiat InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION LP Kettle Boiler ‘The Rotor Air Cooler is a kettle boller. Rotor cooling ai, extracted from the gas turbine compressor, is circulated through the cooler. The air from the discharge of the compressor is directed through the Rotor Air Cooler and temperature is controlled by the bypass valve. The system functions to maintain outlet air from the Rotor Alr Cooler at the following setpoints: Load | Setpoint | Alarm High | Unload | Load Dump | Trip 200 | 208% mse | as 2690 <85% Brees 2s ST x as%woom | ZO aPC WSC [RAC 253.5C noe PSO [RE [Rae ae a '"load Is > 26% normalized load and RAC outlet temperature is less than (93°C) or both thermocouples show bad quality an automatic unload signal is generated and "Rotor Cooling Air T/C Trouble" alarm will initiate, Rotor Air Cooler Filter ‘The cooled air is returned to the engine for internal rotor cooling through an air filter, ‘The rotor cooling air fiter consists of an integral stainless steel separator built into a Pressure vessel. Dirt particles are removed from the rotor cooling alr to prevent Impingement damage to gas turbine internal components, Removal ofthe dirt also helps {o prevent the buildup of particulate matter inside the turbine in areas where critical Clearances exist. As the air enters the filter unit, it makes an abrupt change in direction. Dirt particles can not make the abrupt inertlal force. Approximately 5% ofthe air that enters the filter, together with any Separated dust, is piped into exhaust system via the high pressure bleed piping. The other 25% of the air Is directed onto the rotor along the torque tube housing. ‘ction change and are separated frorn the air by Page 20 6134 FOR TRAINING ONLY 12 Turbine aindoe ‘Siemens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION SGT6-SO00F COMBUSTION TURBINE BLEED AND COOLING AIR SYSTEIVS — ti im kezensrene Turbine Cooling Air System ‘Thermocouples are installed to determine temperature conditions within the turbine section. These thermocoupies transmit signals for indication and control of the temperature regulating valves. Two thermocoupies are installed upstream of row 2 {turbine dises (Disc Cavity 2), two thermocouples are installed upstream of row 3 turbine discs (Disc Cavity 3), and two thermocouples are installed upstream of row 4 turbine disos (Disc Cavity 4). If the Disc Cavity 2 thermocouples indicate that the temperature exceeds a set point of 435°C, a warning alarm is initiated. If the Disc Cavity 2 thermocouples indicate that the temperature exceeds a set point of 440.5°C, a turbine automatic unload sequence will begin. If the Disc Cavity 3 thermocouples indicate that the temperature exceeds a set point of 435°C, a warning alarm is initiated. If the Disc Cavity 4 thermocouples indicate that the temperature exceeds a set point of 399°C, a warning alarm is initiated. If the Disc Cavity 5 thermocouple indicates that a temperature exceeds a set point of 413°C, a warning alarm is initiated. If Disc cavity 5 Pago 18 of34 FOR TRAINING ONLY 12 Turbine alrdoc ‘Slemens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION ‘Such bleeding reduces the air flow through the compressor down-siream of the bleed ports, which lowers the velocity of the air to the point whare the last stages can function effectively, equalizing the work of compression throughout all stages of the compressor. Turbine Cooling Air System The Turbine Cooling Air System performs two basic functions. The first function Is to provide direct cooling of components exposed to hot gas path temperatures that are higher than material temperature limits, The second function is that of turbine _eenvironmental control. A\ir at the correct pressure and temperature is provided at various critical points to ensure that the design environment is maintained throughout the turbine. A large percentage of the cooling air is supplied to satisfy seal leakage requirements. By having a positive flow of cooling air toward the gas path, hot gases are excluded from the shell support structure and the turbine blade path disk areas. ‘The turbine stationary vanes and disc cavities are cooled by compressor discharge and bleed air, The first stage vanes use compressor discharge air routed internally through the combustor section of the turbine. This air passes from the outer shroud into the hollow core of the vanes and exits through the internal passages in the vanes to the trailing edge of the vanes. ‘Second stage vanes and row two disc cavities utilize the 11th stage compressor bleed air that flows from a manifold on the compressor section, to the turbine cylinder section, through piping external to the unit. When air enters the turbine section it passes from the outer shroud, through the vanes, and through an inner shroud into the disc cavity. ‘Some of the cooling air also exits the vanes through passages to the trailing edge. The ‘amount of cooling airflow to the second stage vanes and row two disc cavities is regulated by means of a regulating valve connected in parallel with a fixed orifice. ‘By moni ing actual disc cavity temperatures, the valve can either be opened to provide more cooling flow, or shut te reduce the amount of cooling flow: The regulating valve is designed to control the dise cavity temperature at 413°C. Page 16 of 34 FOR TRAINING ONLY 12 Turbine alrdoc ‘Slomens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION inlot and Variable Guide Vanes To improve acceleration and compressor surge margin, or stall, during startup and shutdown, the gas turbine is equipped with compressor bleed valves and variable guide vanes upstream the compressor stages 4, 2, 3 and 4. Compressor bleed valves and variable guide vanes function together to limit the airflow and control pressures in the compressor during starlup and shutdown. The inlet guide vanes (IGV) are located on the compressor inlet casing assembly immediately upstream of the 1st stage compressor blades, the variable guide vanes (VGV1, VGV2 and VGV3) upstream the 2nd, the 3rd and the 4th stage compressor blades. The vanes are positioned by the turbine control system as a function of the speed of the turbine during startup and as a function of load and/or exhaust temperature during operation. ‘On turbine shutdown, either normal or emergency, the guide vanes are closed immediately following the fuel-off signal. IGV and VGV Actuator ‘The guide vane actuators are attached to bottom of the compressor casing. The actuators are double acting hydraulic piston assemblies with an infegral servo valve controller and position feedback sensor. Each linear IGV, VGV1, VGV2 and VGV3- actuator moves a circular actuating ring, which is attached to each of the guide vanes by a mechanical linkage. Movement of the actuator causes the guide vanes to rotate In unison, IGV and VGV Position Transmitter Each device, mounted on the end of the inlet resp. variable guide vanes, converts the angular motion of the vane to an analog signel which is input to the control system. This allows accurate monitoring of the position during turbine operation. Pago 14 of 34 FOR TRAINING ONLY 42 alrdoc ‘Slemens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION ‘The air then flows through the inlet shutoff damper located in the intake duct prior to entering the compressor inlet casing. This damper isolates the filter house from the gas turbine intake path to prevent ambient moisture from corroding moisture sensitive components during shutdown. The shut-off-flap consists of a blade segment arranged upstream the compressor in the airflow of the duct. In the "closed’-position the damper blade shuts the duct by swivelling from vertical to horizontal position. Here the damper is sealed by means of a stainless steal lip opposite of the intake duct. To avoid corrosion, the companion part of the duct is also equipped with a stainless steel plate. Limit switches monitor the position of the damper. During gas turbine startup the dampers are commanded open by the Gas Turbine Sub Group Controller (early in the startup sequence. A protective signal is also sent to command open the damper if gas turbine speed exceeds about 240 RPM. If the damper does not open the control system wil interrupt the startup sequencé. The dampers close approximately 2 hours after the gas turbine is shutdown. At this point the dehumidification system is placed in operation to control the humidity at the compressor inlet. : During standstill periods the condensation from the vi ir dryer system reduces the humidity and removes iy of the vertical intake duct to prevent corrosion of moisture sensitive components. This is a self contained system with intake and return ducting to the intake duct just upstream of the compressor inlet. This system draws moist alr from the compressor inlet and passes the air through a desiccant wheel removing excess dd air is then retumed to the compressor inlet. A second blower draws atmospheric air into the dehumidifier, heats the air and passes the heated air over the desiccant wheel to remove the moisture. This moisture laden air Is then returned to the moisture. The atmosphere. Page 12 of 34 FOR TRAINING ONLY 42 Turbino alrdoe ‘Siemens Confidential InformationInternal flashing kits made of lighter gauge stainless steel are provided to close gaps between the coils to ensure all inlet air passes through the coils by eliminating air flow around the coils, ‘Two supply distribution manifolds are required, one on each side of the cooling coil system. Each supply distribution manifold includes a flange at the bottom for connection of supply piping by others. ‘The return distribution manifold is a vertical pipe. Individual coil connections on the manifold are match marked for field fit. Two return distribution manifolds are required, ‘one on each side of the cooling coil system. Each return distribution manifold includes a flange at the bottom for connection of return piping by others. Chiller Coils Drift Eliminator The drift eliminator panels separate moisture from the incoming clean air. The panels are ‘comprised of sine-curve-shaped flow contours assembled with phase-separating chambers. The profiles split the alr flow and turn it in a tight radius that allows the air molecules to flow through the panel but not the liquid. As the drops contact the profile Pago 10 of 34 FOR TRAINING ONLY 12 Turbine alr.doc ‘Slomons Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION Four methods can be used to pulse clean the filters; automatic, high humidity, manual, or timed. With the control switch set in the “Auto” position, the pulse system will start a pulse cycle, one of the following conditions is met: * Filter pressure drop exceeds the settings of the pulse controller * Environmental humidity exceeds the settings of the puise control system ‘Two manual setting s are available as follows:. * Auto Timed is selected for a specific time to start + Manual for continuous pulsing of fitters a ie > cc NE TEESE Uae ee Pulse cleaning Air Inlet Alarm Setspoints Air Inlet Differential Pressure switch provides high alarm at 152.4 mm, indicating clogged or ditty filters. Air Inlet Pressure Switch at the compressor inlet manifold provides an Page 8 of34 FOR TRAINING ONLY 42 Turbine airdee ‘Slomens Confidental InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION ‘The bus modules on the headers trigger the solenoid valves in accordance fo the set pulse width and interval time. A common serial IMC bus connects the bus modules in daisy chain with one another and the PLC, The PLC monitors the correct functioning of the pulse solenoid valves via the resulting air flow variations in the main feeding line of the filter house. A missing air flow after triggering the solenoid valve indicates a defective valve or stuck diaphragm, while a remaining air flow after closinig a solenoid is an indication for a leak in the valve seat or the diaphragm. In addition the current through the valve is monitored by the corresponding bus module If the local humidity will Increase about a set value 80% the dust cake on the filter cartridges can get more stuck and may bake on the filter surface after drying. Therefore the system is fitted with an additional humidity sensor to release a cleaning cycle under these weather conditions, even if the filter pressure drop is below the set value. The system will carry out one complete sweep, stop and wait for 300 sec. If the break time has expired, the system will start another complete cycle, if humidity is still> 80%... Page 6 of 34 FOR TRAINING ONLY 12 Turbine alrdoc ‘Stomens Confidential InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION Inlet Filters The inlet air enters the system al the front of the filter housing equipped with a pair of high efficiency conical and cylindrical pulse fiter cartridges and into a clean air plenum of the module, The pulse cartridge filter is a pair of cartridges installed horizontally, back-to- back and sealed against the vertical grid plate that separates the clean airside from the dirty air side. The cartridge closest to the grid plate is a conical element; the other cartridge is a cylindrical element, The filter cartridges are supported on an internal horizontal yoke and clamped tightly against the grid plate, Thé cartridges are cellulose media, with each pair of cartridge filters including one straight and one conical shaped cartridge. The filter media is capable of removing 99% of all particles two microns and larger. The filters are installed so that any individual filter can be replaced while the turbine is in operation. There are 864 element pairs. Spider Web provides maximum protection against very small dirt/dust particles, those that typically cause blade fouling without adding significant differential pressure. Clean Air Gasket Tubesheot Gonlcal Filter Element Gasket Cylindrical Fitter Element Fliter Elements > -_ As contaminants build up on the surface of the filter media, the differential pressure in the plenum will increase. When the differential reaches a preset limit of 684 mBar , a Page 40f 34 FOR TRAINING ONLY 12 Turbine altoe ‘Slomons Contidentat InformationQURAYYAH IPP PROJECT - GAS TURBINE FAMILIARIZATION Design Basis Sufficient quantities of air, at the correct temperatures and pressures are vital to the proper operation of the gas turbine and almost ail of its associated systems. The turbine alr systems are designed to provide and control the flow of air to meet the gas turbine’s operational requirements. DESCRIPTION inlet Air System This inlet air filter system is a single sided designed for the Siemens SGT6-5000F(5) gas turbine. itis 8 modules wide and 27 elements high. The modules are arranged to allow 30,356 m*/min of air to enter the vertical side of the arrangement, There are a total of 864 pairs of filters. The transition outlet of the unit is connected to the inlet duct system, where 30,356 m*/min of clean air is directed to the gas turbine for combustion. SLOPED ROOF: "TWO SHEET ‘cruLER cous ‘Tea UGHTS: ‘weaTHER 40008 wi: GHY, BD SCHED COnESONG PREALTERS ew PONT TRASMATTER uscieccos? ew FoRUT TeANSMeTTER p.tocades Furr srr (contro Box { Inlet Air System Page 2 of 34 FOR TRAINING ONLY 42 Turbine aledoe ‘Siemens Confidential information