| The BASIC DESIGN
Content
Section One QDR20 gas turbine engine
generator set
1. General
2. Main equipments
2.1 Gas turbine engine
2.2 Generator
2.3 Shaft coupling
3. Main assistant system
3.1 Air inlet filtration system
3.2 Exhaust system
3.3 Ventilation system
3.4 Lubricating oil system of gas turbine engine
3.5 Lubricating oil system of generator
3.6 Fuel system
3.7 The fire extinguishing system in acoustic enclosure
3.8 Starting system
3.9 Excitation system
3.10 Control and measure system
3.11 Mcc system
3.12 Direct current
4. Waste heat recovery boiler
section two CO-generation power station design
General
Fuel system
Cooling water system
Boiler
High voltage
Low voltage
Direct current
Communication
The fire fighting
Environment protection
Section One QDR20 gas turbine engine generator set
1. General
QDR20 gas turbine engine generator set uses WJ6G1 gas turbine engine burning nature gas or other fuel as driving machine driving generator to generate electricity. According to consumer’s needs, high temperature exhaust from gas turbine engine may enter into waste heat recovery boiler to produce steam in order to be co-generation or combined cycle sets.
QDR20 gas turbine engine generator set is of containerized enclosure type, installed outdoor on the foundation by bolts.
QDR20 gas turbine engine generator set mainly consists of gas turbine engine, generator, engine starting system, shaft coupling, engine main support mount, engine supplement support mount, acoustic enclosure, base, air inlet filtration system, exhaust system, ventilation system, lubricating oil system of gas turbine engine, lubrication oil system of generator, fuel system, fire extinguishing system in the acoustic enclosure, starting system, excitation system, control and measure system etc.
QDR20 gas turbine engine generator set is installed in acoustic enclosure divided into two zones or cells in order to manage equipments with sub-area and improve sub-area ventilation efficiency within these two cells. Outline dimension of the acoustic enclosure are 9000mm(length)x2438mm(width)x2800mm(height).
Main equipments including gas turbine engine, generator and starter etc are installed on one whole base and connected with each other by shaft coupling. Modules of Lubrication oil system of gas turbine engine, lubrication oil system of generator and fuel system are installed in the whole base. Gas inlet filtration silencer system of gas turbine engine and enclosure ventilation system are installed on the top of the acoustic enclosure.
The acoustic enclosure is a welding three-dimension structure with profiled bar and steel board. The acoustic enclosure fits in with intensity requirements and vibration mechanics norms and ensures sound insulation effect with absorbing sound material in interlayer structure and perforation steel board on inner surface. Rubber damp slice is pasted between acoustic enclosure and common base or door in order to reduce vibration and structure sound. Doors are installed in appropriate acoustic enclosure position in order to disassembly and service equipments.
Crane installed in the acoustic enclosure can lift gas turbine engine or other equipments out of the acoustic enclosure for installation and overhaul requirements. In addition, four dismountable suspender rings are installed to suspend the whole acoustic enclosure for transportation and installation.
2. main equipments
2.1 the gas turbine engine
WJ6G1 gas turbine engine is a single shaft gas turbine engine improved on the base of WJ6 aeroengine made by south aeroengine company of china. This gas turbine engine has been tested many times and has got satisfactory test results. Profound and rich experiences in its operation have been accumulated. It is a perfect power plant for power station with advanced structure, perfect technique, reliable quality and long life.
WJ6G1 gas turbine engine consists of reduction gearbox, transmission gearing, compressor, combustion chamber, turbine etc.
The compressor is a ten stage axial subsonic compressor with single rotor and it includes three parts: stator, rotor and inlet guider. In order to guarantee the stability when gas turbine engine starts and accelerates, two bleed valves are respectively set on the fifth and eighth stage of compressor. The closing and opening of each valve are automatically controlled by micro-computer system according to the pre-selected rotating speed. The combustion chamber is a mixture combustion chamber with ten nozzles, consisting of combustion chamber housing, flame tube, working nozzles, igniter and fuel manifold. The combustion chamber has the following technical performance: uniform combustion temperature, little loss of pressure, high combustion efficiency, small dimensions, light weight and long life.
WJ6G1 gas turbine engine has the following technical feathers:
| Output shaft rotor turning (seeing from inlet air): |
clockwise |
| Rotor speed of output shaft |
1000 r/min |
| Inlet air flow |
19.67kg/s |
| Pressure ratio |
7.04 |
| Exhaust temperature |
<450°C |
| Max output power |
2350kW |
| Rated output power |
2130kW |
| Fuel consumption(at rated working condition) |
15.65MJ/KW.h |
| Naked engine weight |
1120kg |
The generator is brushless excitation, 3-Phase synchronous generator.
| Model: |
TFW3125-6/1430 |
| Rated voltage: |
6300V |
| Rated frequency: |
50Hz |
| Rated power: |
2500kW |
| Rated power factor: |
0.8( lag ) |
| Rated rotate speed: |
1000r/min |
| Excitation mode: |
brushless |
| Protection Class: |
IP21 |
| Insulation Class: |
F |
The generator has two slip bearings .Cooling manner is air cooled mood.
Rotary direction: seeing from the transmission shaft (gas turbine engine), counter-clockwise rotation.
The generator stator winding has 6 units of Pt100 temperature transducers, foreside and rearward bearing has Pt100 temperature transducer.
2.3 Shaft coupling
The superposition flake flexibility shaft coupling is used between gas turbine engine and the generator. The technical data are as follow:
Type: TDP8-3300-00T4
Allowable Max rotor speed: 5250RPM
Normal twist torque: 31500Nm
Max axial supplementary value: at angle 0.13: positive/negative 3mm
at angle 0.5: positive/negative 1.5mm
Flexible circular pin shaft coupling is used between gas turbine and generator. The technical data are as follows:
Allowable Max rev: 4000r/min
Normal twist torque:1250Nm
3. Main assistant system
3.1 Air Inlet Filtration System
3.1.1 General
(1) The gas turbine is fitted with an inlet filter to limit ingestion of undesirable objects, particles and elements etc.
(2)The design and selection of an air filtration system well considers the influence of site soil, wind conditions, rainfall, snow accumulation and other environments.
(3) The air filtering system selected mainly considers its efficiency and designed pressure drop. The inlet pressure loss should be minimized in the filter. The designed pressure drop is from 50mmH2O to 75mmH2O.
(4) Air inlet filtration consists of a two-stage filter, the first stage filter mainly consists of Snow Hoods with bird screens that remove the larger particles. The second stage filter mainly consists of the Self Cleaning Filter, and control the flow velocities through the second filter of self cleaning type are controlled between 2.5 and 5 m/s.
(5) Inlet air flow: The nature air is drawn into the self cleaning filter through snow hoods with bird screens, then flows through silencer, elbow and ducting etc., finally enters into the engine.
3.1.2 The first stage filter: Snow Hoods with bird screens
Install a snow hood with the inlet vertically down to force the air stream to flow upwards as it enters the system. This prevents large water droplets, wet snow, particles and birds etc. from entering the inlet.
3.1.3 The second stage filter: The Self Cleaning Filter
A self cleaning filter mainly consists of high efficiency cellulose media and pulse type back blow system.
The back blow system works in a way that compressed air inside the cartridges momentarily reverses air flow direction and dislodge accumulated dusts precipitated on the wall of the filter drum. Compressed air flow is about 0.4m3/min, and pressure is about from 0.4 to 1.0MPa.
Since not all the filter drums are back blown simultaneously, the primary air intake to the gas turbine is not disturbed significantly during the back blowing. The self cleaning filters can remove particles 5 microns or larger with at least 99.5% efficiency and remove all particles larger than 20 microns
3.1.4 Pressure Switch
A pressure switch installed is to measure differential pressure between atmosphere and the engine inlet plenum. This switch is interlinked with turbine’s control unit, which will shut down the engine if the filters become blocked and differential pressure reaches to 100mmH2O. That the blockage has to be cleared before the engine restarted can only activate the reset of the pressure switch.
3.2 Exhaust System
The gas turbine engine exhaust duct has a flanged outlet.
The total exhaust flow of the gas turbine engine at loads is not more than 20.4Kg/s. The total exhaust pressure losses between the gas turbine engine exhaust flange and the final outlet to atmosphere are not more than 200mmH2O at load. The estimated non-attenuated exhaust sound power levels in the audible frequency range at various load conditions is less than 85 dB(A).
In order to prevent injury to personnel from high temperature who might come into contact with the exhaust system, the outside skin is paved with thermal preservation layer.
In order to allow growth due to thermal expansion, or to allow tolerance from installation, the exhaust system is fitted with an expansion joint. The expansion joint can also limit the forces imposed on the gas turbine engine.
3.3 Ventilation system
The ventilation system the main function is to give the incoming airflow ,cooling the gas turbine, electrical components and diluting the fuel gas concentration (in the event of a gas leak). In the event of gas being detected within the enclosure, continued operation of the ventilation system ensures that the gas is extracted and diluted by the incoming airflow. The ventilation system divided into alternator room ventilation system and gas turbine room ventilation system
3.3.1 Alternator room ventilation system
3.3.1 Main parameter:
Quantity of air flow : 6.3m3/s
Main pressure lose: 20mmH2O water gauge
Filtration precision: 200 micron
Noise lever: less than 85d B(A)
3.3.1.2 The main components:
Motor, Ventilation inlet damper, Ventilation outlet damper, filter web, ventilation ducting, ventilation cover, pressure different transducer.
Generator room ventilation adopts blow at inlet�?/FONT>this part is positive pressure .It is effective to prevent gas (in the event of a gas leak) entering into the gas turbine room. When the fan starts working, airflow goes through filter screen, fan, inlet damper into enclosure and then emits into the atmosphere through outlet damper, ventilation ducting. Inlet damper and outlet damper are interlocked with the fire control system. The inlet and outlet damper is opened in normal working condition, when fire risk signal was detected within the enclosure, the damper will be closed.
3.3.2 Gas turbine room ventilation system
3.3.2.1 Main parameter:
Quantity of airflow : 5.4m3/s
Main pressure lose: 20mmH2O water gauge
Filtration precision: 120 micron
Noise lever: less than 85d B(A)
3.3.2.2 The main components:
Motor, Ventilation inlet damper, Ventilation outlet damper, filter web, inlet silencer, outlet silencer, ventilation ducting, ventilation cover, pressure diff. transducer.
When the fan started, airflow enters into the ventilation cover, and through the inlet silencer into the filter screen. Ventilation cover can prevent the rain, snow, water from entering into the ventilation ducting, filter screen can prevent the catkin, leaves, paper and other sundries to inhale. Airflow goes into the enclosure through ventilation inlet damper, and then through the Ventilation outlet damper, fan, outlet silencer, ventilation ducting the air flow is exhausted into atmosphere. Inlet and outlet dampers are interlocked with fire fighting system.
3.4 Gas Turbine engine Lubricating Oil System
Gas Turbine engine Lubricating Oil System is designed to supply lubricating oil with a certain pressure and temperature, to lubricate and cool the turbine thrust and journal bearings.
Parameter of this system is as follows:
Type of lubricating oil: WJ-20 synthetic hydrocarbon lubricating oil
Guideline of lubricating oil
Kinematics Viscosity, at 100°C: 4.3-4.7(mm2/s)
Ash Content �?.005�?/FONT>,
Carbon Residue �?.15�?/FONT>
Acid Number (mgkOH/g) �?.05�?/FONT>
Flash Point �?35°C
Solidifying Point �?35°C
Condensing point: �?35°C
Density at 20°C g/cm �?.87
Inlet Temperature : 50°C-65°C
Filtration precision /FONT>10 micron
Consumption of lubricating oil �?/FONT>0.8 L/h
Circulation Flow �?20 L/min
Oil Supply pressure : 0.018Mpa
The main components:
Including oil tank, pump, filter, cooler, temperature sensor and connected pipe, valve and instruments.
Oil tank is fixed on the skid base. The pumps are used for feeding oil to the gas turbine engine and providing cooling and lubricating for the gas turbine.
3.5 LUBRICATING OIL SYSTEM OF GENERATOR
Oil lube system of generator is used to cool and lubricate bearing bush�?/FONT>remove heat released from the machinery generated from friction. And at the same time it will reduce the static friction moment during starting.
3.5.1 parameter of lubricating oil
The oil type: L-AN46
Kinematics Viscosity( 40°C): 41.4-50.6(mm2/s)
Condensing Point: �?5°C
Mechanical Impurities: �?.007%
Flash Point: 160°C
Oil feeding pressure: 0.02Mpa
Flow: 25L/min
Feeding Temperature: 25-40°C
Filtration precision: /FONT>10 micron
3.5.2 The main components Include oil tank, electricity heater, cooler, pump, solenoid valve, high position oil tank, filter, pressure indicator, temperature indicator, temperature sensor and connecting pipings, valve.
3.5.3 Process flow
In order to prevent the dry operation friction between generator shaft and bearing bush, lube oil will be extracted by pumps and implement its oil filling and oil jacking under the control of solenoid valve. And five seconds later lube oil will be pumped back to main pipe circuit under the control of solenoid valve. Lube oil will go through filter and then to radiator, and finally will be sent to the lube inlet of generator shaft support by the high position oil bank. After the lubricating work finished, lube oil will return to oil bank by force of height potential difference and ready for next cycle. The high position oil tank capacity can not be less than 5 minutes as it is used to for emergency lube supply.
3.6 Fuel System
Fuel system is referred as the fuel supplying system for single gas turbine engine generator set, the system is installed within the whole base structure and consists of three pneumatic ball valves, two shut-off valves, instruments and piping. Fuel regulating valve regulates fuel gas flow of the gas turbine engine by conducting commands from controller.
Main parameters of the fuel system are as follows:
Fuel Medium natural gas
Fuel gas pressure 0.9MPa
Fuel gas temperature: �?/FONT>50°C
Fuel gas calorific value �?36.16MJ/Nm3
Fuel gas flow 908Nm3/h
Fuel gas quality requirement meets the next table:
|
NO |
Name |
Limit content |
|
1 |
Total solid particle impurity content (maximal) |
30ppm(quality calculated)), subsiding velocity in air higher than 6mm/s is lower than 1%, subsiding velocity higher than 10mm/s can not exceed 0·1% (particle average equivalent ball diameter is 8�?/SPAN>10μm) |
|
2 |
Liquid state hydrocarbon and gas fuel hydrate |
The highest condensation temperature is at least 28�?/SPAN> lower than fuel system’s lowest temperature |
|
3 |
Water content |
�?/SPAN>112 kg/million m3 |
|
4 |
Hydrogen sulfide (maximal content) |
10mg/Nm3 |
|
5 |
Sulfur alcohol content |
0.001 mol% |
|
6 |
Nitrogen oxide (maximal content) |
25mg/Nm3 |
|
7 |
Ammonia (maximal content) |
25mg/Nm3 |
|
8 |
Naphthalene (maximal content) |
25mg/Nm3 |
|
9 |
Natural gas supplied pressure |
�?.09Mpa |
|
10 |
Natural gas supplied temperature |
�?5�?/SPAN> |
|
11 |
Supply flow |
�?352Nm3/h |
|
12 |
Thermal value |
�?650 kCal/Nm3 |
Attached drawing<fuel system flow drawing of the set>
3.7 Fire Protection System
3.7.1 The HFC227ea (molecular formula is CF3CHCF3) gas automatic fire extinguishing system is adopted in the acoustic enclosure. The fire extinguishing system mainly consists of:
. one set of immovable fire extinguishing system out of the acoustic enclosure, including one 47kg cylinder of HFC227ea and other required auxiliaries, supplied by customer
. piping and two nozzles installed in proper position of the acoustic enclosure,
. an automatic fire alarm system.
3.7.2 The automatic fire alarm control system consists of the smoke detector, overheat detector, manual alarm push button, audible/visual alarm, connective interface and fire alarm controller, etc. The alarm system should be available for automatic, manual, and mechanical emergency modes. The acoustic enclosure is divided into two zones or cells namely, gas turbine engine zone and the generator zone. The gas turbine engine zone includes one smoke detector, one overheat detector, one manual alarm button, two audible/visual alarms etc. Every generator zone includes one smoke detector, one overheat detector, one manual alarm button, two audible/visual alarms etc.
3.8 Start System
3.8.1 General:
The starter of the gas turbine engine is a 3-ph, AC, asynchronous electromotor.
Power supply of the starter is provided by a 90kW, 3-ph, AC converter.
Startup Type of a gas turbine engine: crank and starting.
Crank time: 30s, rotary speed�?/FONT>19%.
Ignition rotary speed for engine start-up is 15-21%, rotary speed when converter detachment speed higher than 60%.
3.8.2 Equipment parameters
Starter parameters:
Type: 2-315L2-10
Rated Power: 75Kw.
Rated Input: 3*380VAC, 50HZ.
Rate Speed: 590r/min.
Rated Current: 162A.
3.9 Excitation System
Excitation system consists of automatic voltage regulator and generator.
Generator additive loop supply low voltage alternating current to the automatic voltagge regulator, automatic voltage regulator transforms the alternating current to direct current,adjust the direct current according to voltage and current of the generator or the request of the controller,send the direct current to the exciting loop of exciter,then the generator produce high alternating voltage, automatic voltage regulator can adjust the hight votage and reactive power of generator according to the request of load and controllers.
Excitation systemic function:
Excitation control on/off switch,fault indicator:
Excitation hand/auto switch:
Manual raise/lower volts switch
Volt/PF control selector switch
Automatic voltage regulator raise/lower volts switch:
Diode failure indicator:
Over excitation limit indicator:
Excitation in manual indicator:
Excitation tripped indicator:
Exciter field ammeter and voltmeter.
3.10 Control and measure system
3.10.1 Function of the control system:
The control system mainly realizes control and protecting of the whole QDR20 package. It provides:
Gas turbine Start, crank, increasing speed and power control during generating electricity.
Lube oil system control
gas turbine vibration Monitoring
Generator Protection control
Generator auxiliary system control
Recovery boiler control
The other auxiliary system control
Package alarm, emergency stop control
Human machine interface (HMI)
3.10.2 Structure of the control system:
The control system consists of GTCON2000 controller, HUB, HMI etc.
3.10.2.1 GTCON2000 control system
GTCON2000 control system is an integrative gas turbine package control system .It can provide gas turbine control, generator control( AVR and synchronization control ) , recovery boiler and the other auxiliary system control. It is DCS structure and has many year use experience and has been tested for many years. The system fully integrates, the system modules can be inserted and pulled out online. The rotate speed has over speed protection circuit independent of processor. The temperature module has over temperature protection circuit independent of processor. The synchronization module and DPU have synchronization function, can prevent from mistake synchronization.
Every package use a GTCON2000 redundant controller installed in a control cubicle. The controller hardware consist of DPU (processor)module, DI (digit input) module, DO( digit output )module, TC module, RTD module, SD( rotate speed measure ) module, VC( servo control )module, SYN( synchronization )module.
The controller work power is 24VDC.The control system support two power supply. One is 24VDC from DC cubicle, the other is from UPS 220VAC,the AC 220V transit 24V stable voltage module, get 24VDC power. 220VAC power from MCC transit controller inner UPS, then provide power for HUB and HMI.
CPU module has Ethernet communication interface.
Control software is Tristation1131, the control programme can be 100% downloaded and installed online .
3.10.2.2 HMI
HMI provide friendly human machine interface. HMI is one PC, HMI and GTCON2000 controller are installed in a control cubicle. HMI monitoring software is INTOUCH configuration software, include main menu, history alarm menu, history trend menu, history data menu etc. .In HMI can display all measure, running state parameter. It looks more concentrative, friendly, beautiful than instrument interface. At the same time it will provide history data saving for one year. HMI and GTCON2000 controller communicate via Ethernet, communication protocol is DDE.
3.10.3 measure system
The measure parameters of the package include electricity and non- electricity parameter. Here only show non- electricity parameter measure transducer, mainly include temperature, pressure,
vibration ,liquid surface, rotate speed etc.
Transducer list:
ENGINE
parameter
|
type |
Lube oil
pressure |
gas pressure |
Shaft cavity
temperature |
T4 temperature |
Rotate speed |
Return oil
temperature |
Oil tank
Liquid surface |
vibration |
|
Signal type |
CS1151GP4-20mA |
CS1151GP
4-20mA |
Pt100 resistance |
MGR-5 K Thermal couple |
GZT-1 pulse |
Pt100
resistance |
UQK-01
digit |
GGZ-1B
4-20mA |
|
alarm |
< 0.4 MPa |
<0.75 MPa |
> 135°C |
> 720/475°C |
<90 %�?gt;97.6 % |
> 75°C |
< 110 mm |
> 3.5 g |
|
Emergency stop |
< 0.3 MPa |
<0.65MPa |
|
start/work |
Low speed/over speed |
|
<80 mm |
|
|
remark |
|
|
|
|
|
|
|
|
GENERATOR
|
type |
Lube oil pressure |
Foreside Bearing
temperature |
Rearward Bearing
temperature |
Winding
temperature |
|
Signal type |
CS1151GP
4-20mA |
Pt100
resistance |
Pt100
resistance |
Pt100
resistance |
|
alarm |
< 0.04MPa |
> 60°C |
> 60°C |
> 80°C |
|
Emergency stop |
< 0.03 MPa |
> 70°C |
> 70°C |
|
|
remark |
Perhaps
adjusted |
|
|
|
3.11 Motor control centre
Motor control centre supply electrical energy to pumps,heaters, control instruments,
Unit load as follows table:
Unit load list
|
|
Engine oil pump |
Generator oil pump |
Adjust oil pump |
Engine oil heater |
Generator oil heater |
Ventilation
fan |
Tank lighting |
total |
|
Power(kW) |
1.1 |
2.2 |
1.1 |
3 |
3 |
7.5 |
1 |
|
|
number |
1 |
1 |
1 |
1 |
1 |
2 |
1 |
|
|
work number |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
|
|
calculate power(kW) |
1.1 |
2.2 |
1.1 |
3 |
3 |
7.5 |
1 |
11.6 |
|
reactive power(kVar) |
|
|
|
|
|
|
|
8.7 |
|
Capacity(kVA) |
|
|
|
|
|
|
|
14.5 |
3.12 DC system
DC control power supply of engine is 24VDC, and carry out emergency supply power.
Loads of DC control power supply: normal 5A, instantaneous max 15A.
DC control power supply is provided by DC system of powerstation.
4. Waste heat recovery boiler
The main equipment of waster heat recovery boiler : Water feed pump , inlet expansion joint, inlet duct , evaporator, superheater, economizer , deaerator evaporator, drum, safety valve, outlet duct, outlet expansion joint, joint duct , valve , platform , sampling, sampling set, test and control instrument
Technical performance of waste heat recovery boiler :
Temperature of steam : 190°C
Pressure of steam: 1.0MPa
Quantity of steam : 6.3 t/h
Resistance of gas: 180 mm water gauge
Temperature of exhaust :�?40 °C
Working flow:
The deoxidized water after through the deaerator divided into two ways , one way is that deoxidizing water with 105°C, 6.6t/h is sent to economizer by feed pump . After further heated through natural circulation between steam drum and evaporator of waste heat recovery boiler, deoxygenated water shall generate steam-water mixture that shall be sent to steam drum again for separation. The saturated water separated shall go on circulation and saturated steam shall be sent to the super-heater of waste heat recovery boiler where superheated steam shall be produced for supplying owner for heating system.Which produce steam-gas with 1.0Mpa, 190°C, 6.3t/h, than sent to the user. The waste water will drain to the sewage well by pipe. Another way is that deoxidizing water with105°C, 945kg/h is sent to the deaerator evaporator by feed pump to heat ,which produce the steam with 0.12MPa, 123°C, 900kg/h,and sent it to the deoxidizing equipment. The steam supply the heat energy to deoxidizing deaerator.
To be continued part 2 |
China National
Electric Wire&Cable Imp./Exp. Corp
