GE Oil & Gas MS 5002 C Gas Turbine Manual

GE
Oil & Gas
Operation & Maintenance
MS 5002 C Gas Turbine
Customized for
BURLINGTON RESOURCES–MLN 405
Project

GE
Oil & Gas
This manual contains proprietary information of General Electric -Oil & Gas Company, and is furnished to
its customers solely for customer training courses purposes. This manual 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.
These instructions do not purport to cover all details or variations in equipment, or to provide for every
possible contingency to be met during installation, operation, and maintenance. Should further information
be desired or should particular problems arise that are not covered sufficiently for the purchaser’s purpose,
the matter should be referred to GE Industrial Systems.
Prepared Approved Date:
Elena Casini
GE Oil & Gas
Cesare Sordi
Customer Training Manager
GE Oil & Gas
03/19/2007
Customer Trainer Job: 0620677
Customer : BURLINGTON RESOURCES –MLN 405 PROJECT

GE
Oil & Gas
Sez. A Theory of gas turbine
Sez. B Operation of gas turbine
Sez. C Maintenance of gas turbine
Sez. D Drawing’s of gas turbine
Index
MS 5002 C Gas Turbine
Customized for
BURLINGTON RESOURCES–MLN 405
Project

g GEPS Oil & Gas Nuovo Pignone
PLANT LOCATION: BANDAR ASALUYE
CUSTOMER: LINDE for PARS PETROCHEMICAL - IRAN
GAS TURBINE
MS 5002 D
MAINTENANCE AND OPERATION
TRAINING MANUAL

SECTION 1
INTRODUCTION TO GEPS Oil & Gas GAS TURBINES

INTRODUCTION MS5002C P.1-3
INTRODUCTION
Agasturbineisaninternalcombustionengine.Fromallpointsofview,itcanbeconsidered
aself-sufficientsystem:infact,ittakesandcompressesatmosphericairinitsowncompressor,
increasestheenergeticpoweroftheairinitscombustionchamberandconvertsthispowerinto
usefulmechanicalenergyduringtheexpansionprocessthattakesplaceintheturbinesection.
Theresultingmechanicalenergyistransmittedviaacouplingtoadrivenmachine,which
producespowerusefulfortheindustrialprocessinwhichthegasturbineisapplied.
1 STATIONARYAPPLICATIONS
These applications are the subject of this training course. They are intended for the
followingindustrialservices:
• Generatordrive, inordertoproduceelectricenergybyanopencycle.
• Generatordrive,toproduceelectricenergybyacombinedcycle.
• Generatordrive,toproduceelectricenergy byco-generation.
• Compressordrive
• Pumpdrive
• Pipelinecompressordrive
• Pipelinepumpdrive
• Particularindustrialprocesses

2 MOBILEAPPLICATIONS
Theseapplicationswerethefirsttobeintroducedintermsoftime.Theyincludethe
followingfields:
• railways
• marinepropulsion
• aviation
• roadtraction
3 HISTORICALNOTES
Thefirst gasturbinestobeusedinoperatingapplicationsappearedonthemarketat the
endoftheForties;theyweregenerallyusedinrailways and presentedtheadvantage
ofburningliquidfuel,evenofpoorquality.TheMS3001turbinebuiltbyGeneralElectric,
withanoutputof4500HP,wasusedpreciselyforlocomotiveservice.
Achievementsinmaterialtechnologyandextensiveresearchintocombustionresultedin
rapidimprovementsinperformance,intermsofspecificpowerandefficiency,obtained
byincreasingmaximumtemperaturesinthethermodynamiccycle.
In this matter, three generations of evolution can be defined, distinguished by the
maximumtemperature(°C)rangesofgasesenteringthefirstrotorstageoftheturbine:
Firstgeneration 760<Tmax. <955
Secondgeneration 955<Tmax. <1124
Thirdgeneration 1149<Tmax. <1288
Obviously,toanincreaseintemperaturetherecorrespondedanincreaseinthermody-
namicefficiency,whichpassedfromvalueslowerthan20%inthefirstmachinesto
currentvalueshigherthan40%(LM6000andPGT25+ gasturbines).

4 NUOVOPIGNONEGASTURBINEMANUFACTURINGPLANT
NuovoPignonehasbuiltheavydutygasturbinesforindustrialapplicationssince1961.
These are made in the Florence workshop under a Manufacturing Agreement with
GeneralElectric,Schenectady-N.Y.-USA,which,intime,hasledtotheacquisition
ofcompletelicences(MS5002gasturbine)andtothecompletedesignandconstruction
ofsomegasturbinemodels(thePGTrange).
NuovoPignonealsopackagesaeroderivativeturbinesforindustrialapplications.These
retain the original gas generator design used in aircraft engines coupled to General
Electric(LM)orNuovoPignone(PGT16andPGT25)powerturbines.
Since 1962 up to the present time, Nuovo Pignone has built about 1000 turbines,
completewithallauxiliariesrequiredfortheiroperation;ofthese,agooddealarepart
ofturnkeyplants,forallapplicationslistedinpara.1.1.
Temperature T3 Evolution
in Gas Turbines HD & AO
The rotor blade cooling has been introduced since 50 s in the military
jets and in the HD & AD turbines since 60 s.
5 GEPS Oil & Gas NUOVO PIGNONE GAS TURBINES
Seenextpages.

GE 5 (PGT 5)
Overview
The PGT5 heavy-duty gas turbine has been designed with modular concepts to facilitate accessibility and
maintainability.
The gas generator consists of a 15-stage, high efficiency, axial-flow compressor directly coupled to a single
stage turbine.
The low pressure shaft (two-shaft version) is a single-stage, high-energy turbine, with variable second stage
nozzleswhichgrantmaximumflexibilityformechanicaldriveservice.
The PGT5 has a single combustion chamber system which is rugged, reliable and able to burn a wide range of
fuels, from liquid distillates and residuals to all gaseous fuels, including low BTU gas.
Typical applications include pump drive for oil pipelines and compressor drive for gas pipelines.
Design Info
Compressor
· Axial flow compressor, 15 stages
· Pressureratio9.1:1
Combustion
· Single, reverse flow combustion can
Turbine
Two shafts
· High Pressure turbine one reaction stage
· Low Pressure turbine one reaction stage
Package
· The gas turbine module on a single baseplate includes the engine, starting system, auxilia-
ries and acoustic enclosure
· Std. Configuration (excluding inlet/exhaust ducts/system):
· size8mLxWxH=8.5mx2.5mx3.0m
· weight 28 t
EmissionsControl
· DLE combustion system
· Steam and water injection system
PerformanceInfo
Generator Drive: Single Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT5 5220 kWe 13422 kJ/kWh 24.6 kg/s 524 °C
Mechanical Drive:Two Shafts version (Expected Performance at ISO Conditions with fuel natural gas)
PGT5 5450 kW 13450 kJ/kWh 25.8 kg/s 533 °C

GE 5B (PGT 5B)
Overview
The GE5B series is a 6 MW range industrial duty gas turbine designed in two configurations: A single shaft
configuration for power generation and a two shaft configuration for mechanical drive applications. The
completely new design of the GE5B combines the technology of aircraft engine design with the ruggedness of
the heavy duty PGT class of turbines. The flexibility, simplicity and compactness of the GE5B make it ideal for
industrial power generation, including steam production, Oil & Gas applications in remote areas and Offshore
installations. The control system is configured for fully automatic operation and has provisions for connec-
tion to Remote Monitoring and Diagnostics. The GE5B is ideally suited for applications, which require a
continuous supply of electrical power with high availability and reliability. The exhaust energy is enough to
provide a substantial quantity of steam at various pressures and temperatures when coupled to a Heat
RecoverySteamGenerator.
Design Info
Compressor
· First three stator stages are variable geometry
· Pressureratio15:1
Combustion
· Annular combustion chamber, 18 fuel nozzles
Turbine
· Two reaction stages
· First stage cooled
Package
· The gas turbine module on a single baseplate includes engine, starting system, load gear,
auxiliaries and acoustic enclosure
· The off-base equipment is limited to the lube oil coolers and electric generator
· The inlet filtration module is designed for mounting above the gas turbine enclosure
· The enclosure has wide double-joined doors allowing for ease of access to all turbine
components and auxiliaries or engine removal
· The package design is standardized for quick delivery; custom applications can be provided
· Package dimensions (including filters on top of the enclosure)
LxWxH=5.9mx2.5mx5.7m;Weight=30t
EmissionsControl
· The standard unit is configured with a DLE combustion system
PerformanceInfo
Generator Drive (Expected Performance at ISO Conditions with fuel natural gas)
GE5 5500 kWe 11720 kJ/kWh 19.7 kg/s 571 °C

PGT 10A (two shaft)
Overview
The PGT10 is a high efficiency gas turbine designed and developed by Nuovo Pignone for shaft outputs
ranging between 9,500 and 15,000 HP at ISO conditions. Since first introduced to the market in 1988, the
PGT10 has met its design goals by providing customers with high performance and high reliability and
availability while keeping its design simplicity and easy maintenance concepts. To achieve high efficiencies
over an extended spectrum of power range, an uncommon combination of features has been incorporated into
the design: High pressure ratio, firing temperature level in line with second generation gas turbines, variable
axial compressor stator vanes and power turbine nozzles. The PGT10 combustion system consists of a single
combustion chamber designed for low NOx emissions and is suitable for a large variety of gaseous and liquid
fuels. Typical applications for PGT10 two-shaft gas turbines are not only natural gas compression, centrifugal
pump drive and process application, but also power generation as well as Cogeneration and Offshore applica-
tions.
Design Info
Compressor
Combustion
· Single combustion chamber
Turbine (Two shafts)
· High Pressure turbine two stages
· Low Pressure turbine two reaction stages
Package
· The gas turbine module on a single baseplate includes the engine and a load gear; the
auxiliaries are installed on a separate baseplate joined to that of the gas turbine to form a
single lift on which the sound-insulated enclosure is mounted
· The electric generator is installed on a concrete foundation to limit overall shipping dimen-
sion
· The package design is standardized for quick delivery, but custom applications can be
provided
· Packagedimensions(excludinggeneratorandfilters)9.1mx2.5mx3.0m;Weight:32t
EmissionsControl
· The combustion system is available both in conventional and DLE configuration to satisfy
the most stringent environmental regulations
· Steam and water injection systems are available for NOx reduction and power augmentation
PerformanceInfo
Generator Drive: Two Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
PGT10 10220 kWe 11540 kJ/kWh 42.1 kg/s 484 °C
PGT10 10660 kW 11250 kJ/kWh 42.3 kg/s 493 °C

GE 10B (single/two shaft) (PGT 10B 1/2)
Overview
The GE10 is a high efficiency and environmental friendly Heavy Duty Gas Turbine designed and developed
by Nuovo Pignone for Power Generation (including industrial co-generation) and Mechanical Drive applica-
tions.
Since it was first introduced to the market in 1988, the model PGT10A has been providing high performance,
reliability and availability to worldwide customers while keeping with easy maintenance concepts.
From this starting point, in 1998 Nuovo Pignone launched on the market the high performance version of this
model with two different configurations:
Two shafts for mechanical drive and single shaft for power generation and cogeneration applications.
The GE10 Gas Turbine, with its ability to burn different fuels (natural gas, distillate oil, low BTU fuel), can be
installed in many countries with different environmental conditions: continental, tropical, offshore and desert.
Continuous improvement of the model is carried out with reference to performance and emissions reduction
capability. In this context particular emphasis has been placed on the design of a DLN system for Nitrogen
Oxides (NOx) reduction in order to meet present and future standards for pollutant emissions.
Design Info
Compressor
· First three stages of stator are variable geometry
Combustion
· Single combustion chamber
Turbine
Single shaft GE10/1 Two shaft GE10/2
· Three reaction stages · High Pressure turbine two reaction stages (cooled)
· First two stages cooled · Low Pressure turbine two reaction stages
Package
· The gas turbine module on a single baseplate includes the engine and the load gear; the auxiliaries
are installed on a separate baseplate joined to that of the gas turbine to form a single lift on which the
sound-insulated enclosure is mounted
· The electric generator is installed on a concrete foundation to limit overall shipping dimensions
· The package design is standardized for quick delivery; but custom applications can be provided
· Packagedimensions(excludinggeneratorandfilters)LxWxH=9mx2.5mx3;Weight=40t
EmissionsControl
· The combustion system is available both in conventional and DLN configuration to satisfy stringent
environmental regulations
· Steam and water injection systems are available for NOx reduction and power augmentation
PerformanceInfo
Generator Drive: Single Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
GE10 11250kW 11467 kJ/kWh 47.3 kg/s 490 °C
GE10 11690 kW 11060 kJ/kWh 46.9 kg/s 487 °C

PGT 16
Overview
The PGT16 gas turbine is composed of the twin spool GE Aeroderivative LM1600 Gas Generator coupled with
a rugged, industrial power turbine designed by Nuovo Pignone.
The LM1600 Gas Generator is derived from the F404 turbofan aircraft engine, while the power turbine of the
PGT16 gas turbine is identical to the power turbine of the PGT10 Nuovo Pignone Heavy Duty, high efficiency
gas turbine, which has been in operation for more than half a million hours.
The power turbine shaft speed (7900 RPM) is optimized for direct coupling to pipelines and injection and
process centrifugal compressors with speed ranges that suit all operating conditions.
High efficiency and reliability are just two of a large number of benefits contributing to LM2500+ customer
value.
For generator drive applications the LM1600, coupled to its synchronous generator with a speed reduction
gear, is a highly flexible turbogenerator that can also cover combined cycle/cogeneration applications with an
electrical efficiency close to 50%.
DesignInfo
Compressor
· Twin spool axial compressor (3 stages LP compressor, 7 stages HP compressor)
Combustion
· Annular combustion chamber (18 fuel nozzles)
Turbine
· Twin Spool Gas Generator turbine (1 stage HP turbine, 1 stage LP turbine)
· Two stages Power turbine (7900 RPM) with variable angle first stage nozzles
Package
· The complete gas turbine module is mounted on a single baseplate
· The enclosure is integrated with the baseplate providing maximum accessibility for gas
turbineandauxiliariesmaintenance
· Standard Configuration (excluding inlet/exhaust ducts/system):
· SizeLxWxH=8.1mx2.5mx3.8m
· Weight 19t
EmissionsControl
· Steam or water injection systems for NOx abatement
· DryLowEmission(DLE)combustionsystem
PerformanceInfo
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
PGT16 13735 kWe 10314 kJ/kWh 47.4 Kg/s 493 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
PGT16 14252 kW 9756 kJ/kWh 47.4 kg/s 493 °C

PGT 25
Overview
The PGT25 gas turbine consists of the GE Aeroderivative LM2500 Gas Generator coupled with a rugged,
industrial power turbine designed by Nuovo Pignone. The LM2500 gas generator and the PGT25 power
turbine demonstrated the best overall performances to cover the 17,000-31,000 HP range with maximum
efficiencyabove37%.
The speed of the output shaft, 6500 rpm, as well as the high capacity and simplicity of maintenance have made
the PGT25 highly suitable for driving direct coupled centrifugal compressors for pipeline service or natural
gas reinjection plants. Its light weight and high efficiency makes it well suitable for offshore and industrial
power generation.
The modular design, extended to all accessory equipment, takes into account the special requirements of
platform applications (minimum weights and overall dimensions), as well as drastically reduces erection time
and costs.
The gas generator can be easily dismantled with a simple translation within the package space, thus reducing
the time required for maintenance.
Simplicity of construction and the high quality of the materials employed allow for long intervals between
overhauls and reduced maintenance costs.
Design Info
Compressor
· Sixteen stages axial compressor
Combustion
Turbine
· Two stages Gas Generator turbine
· Two stages Power turbine (6500 RPM)
Package
· The complete gas turbine module comes mounted on a single baseplate
· The enclosure is integrated with the baseplate providing for maximum accessibility for gas
turbine and its auxiliaries maintenance
· LxWxH=9.1mx3.5mx3.7m,Weight38t
EmissionsControl
PerformanceInfo
PGT25 22417 kWe 9919 kJ/kWh 68.9 Kg/s 525 °C
PGT25 23260 kW 9560 kJ/kWh 68.9 kg/s 525 °C

MS 5001
Overview
The MS5001 single shaft turbine is a compact heavy-duty turbine designed for long life and easy mainte-
nance.
The MS5001 gas turbine is the ideal solution for industrial power generation where low maintenance, reliabil-
ity and economy of fuel utilization are required.
Low investment costs make the MS5001 package power plant an economically attractive system for peak load
generation.
The MS5001 is ideally suited for cogeneration achieving very high fuel utilization indexes and allowing for
considerable fuel savings. Typical applications are industrial plants for cogeneration of power and process
steam or in district heating systems.
Design Info
Compressor
Combustion
· Can-annular combustion, 10 chambers
Turbine
· 2 stages
· First stage nozzles cooled
Package
· Complete turbine package mounted on a single baseplate
· Enclosure integrated with the baseplate providing maximum accessibility for gas turbine and
auxiliariesmaintenance
· Standard configuration (excluding inlet/exhaust ducts/system):
· sizeLxWxH=11.6mx3.2mx3.7m;
· weight87.5t
EmissionsControl
· DryLowNOx(DLN)combustionsystem
PerformanceInfo
Generator Drive (Expected Performance at ISO Conditions with fuel natural gas)
MS5001 26300 kWe 12650 kJ/kWh 124.1 kg/s 487 °C

MS 5002
Overview
The MS5002 gas turbine was launched in the 1970s and it has been updated and up-rated along the years to
match the higher power demand.
Presently two versions are available:
MS5002C - 38000 HP at ISO condition
MS5002D - 43700 HP at ISO condition.
The MS5002 is a gas turbine specifically designed for mechanical drive applications with a wide operating
speed range to meet operating conditions of the most common driven equipment, centrifugal compressors and
pumps. It also has the capability to burn a large variety of gaseous and liquid fuels.
Almost 500 units (more than 300 of which were manufactured by Nuovo Pignone) have been installed world-
wide in all possible environments including arctic, desert, offshore, etc., always demonstrating easy operabil-
ity as well as very high reliability and availability. The simple design and robustness of the machine allow for
complete maintenance to be performed on site without the need for special tools or service shop assistance.
Typical applications include Gas Boosting, Gas Injection/Reinjection, Oil & Gas Pipelines, LNG plants and Gas
Storage
Design Info
Compressor
MS5002C
· Sixteen stages axial compressor
MS5002D
· Seventeen stages axial compressor
Combustion
· Reverse flow, multi chamber (can-annular) combustion system (12 chambers)
Turbine
· Single stage Gas Generator turbine
· Single stage power turbine (4670 RPM rated speed) with variable angle nozzles.
Package
· Two baseplates configuration (gas turbine flange to flange unit and auxiliary system.
· Enclosures integrated with the baseplates providing maximum accessibility for gas turbine
andauxiliariesmaintenance
· sizeLxWxH=15.0mx3.2mx3.8m
· weight110t
EmissionsControl
PerformanceInfo
Mechanica Drive (Expected Performance at ISO Conditions with fuel natural gas)
MS5002C 28340 kW 12310 kJ/kWh 126.0 kg/s 515 °C
MS5002D 32590 kW 11900 kJ/kWh 141.3 kg/s 510 °C

PGT 25+
Overview
The PGT25+ gas turbine has been developed for 30 MW ISO shaft power service with the highest thermal
efficiencylevel(approx.40%).
The PGT25+ gas turbine consists of the GE Aeroderivative LM2500+ Gas Generator (updated version of
LM2500 gas generator with the addition of zero stage to axial compressor) coupled with a 6100 RPM Power
Turbine. Built on the LM2500 heritage and with demonstrated 99.6% reliability, the PGT25+ incorporates
proven technology improvements and a large percentage of parts in common with LM2500 in order to deliver
the same outstanding level of reliability. Designed for its ease of maintenance, the PGT25+ also provides a
highlevelofavailability.
High efficiency and reliability are just two of large number of benefits contributing to PGT25+ customer value.
Application flexibility makes the PGT25+ ideal for a range of mechanical drive (gas pipeline etc.), power
generation, industrial cogeneration and offshore platform applications in any environment.
Design Info
Compressor
Combustion
Turbine
· Two stage Gas Generator turbine
· Two stage Power turbine (6100 RPM)
Package
· Gas Generator, Power Turbine and auxiliary System mounted on a single baseplate
· sizeLxWxH=6.5mx3.6mx3.9m(gasturbineandauxiliarybaseplate)
· weight 38t (gas turbine and auxiliary baseplate)
EmissionsControl
PerformanceInfo
PGT25+ 30226 kWe 9084 kJ/kWH 84.3 Kg/s 500 °C
PGT25+ 31360 kW 8754 kJ/kWh 84.3 kg/s 500 °C

MS 6001
Overview
The MS6001 is a single shaft heavy-duty gas turbine. Its design was based on the well proven mechanical
features of the MS5001 in order to achieve a compact, high efficency unit.
The MS6001 is widely applied in power generation applications for base, mid-range and peak load service.
Other typical applications include driving of process machines, such as compressors, in LNG plants.
Combined cycle plants based on MS6001 achieve very high efficiencies with higher availability and reliability
than conventional thermal plants.
Design Info
Compressor
Combustion
· Dualfuelcapability
Turbine
· 3 stages, first two cooled buckets
· First 2 stage nozzles cooled
Package
· Complete turbine package mounted on a single baseplate
· Enclosure integrated with the baseplate providing for maximum accessibility for gas turbine
andits auxiliaries maintenance
· sizeLxWxH=15.9mx3.2mx3.8m;
· weight96t
EmissionsControl
PerformanceInfo
MS6001B 42100 kWe 11230 kJ/kWh 145.8 kg/s 552 °C
MS6001B 43530 kW 10825 kJ/kWh 145 kg/s 544 °C
Experiences
· More than 46 units sold

LM 6000
Overview
TheGELM6000deliversmorethan44.8MWofpoweratover42.7%thermalefficiency.
It is the world’s most fuel-efficient, simple-cycle gas turbine. High efficiency, low cost and easy installation
make the LM6000 the perfect modular building block for electrical power applications such as industrial
cogeneration of utility peaking, both midrange and base-load operations. As an aircraft engine aboard the
Boeing 747, the LM6000 has logged more than 10 million flight hours, with the lowest shop visit rate of any jet
engine.
Continuing the tradition of GE’s LM6000 established record, the LM6000 is ideal as a source of drive-power
for pipeline compression, offshore platforms, gas reinjection and LNG compressors. The LM6000 has been
GE’s first aeroderivative gas turbine to employ the new Dry-Low Emission premixed combustion system; this
system is retrofittable on LM6000’s already in operation. Water or steam injection can also be used to achieve
lowNOxemissions.
Design Info
Compressor
· Low pressure compressor 5 stages
· High pressure compressor 14 stages
· Pressureratio30:1
Combustion
· Annular combustion chamber
Turbine
· High Pressure turbine 2 stages
· Low Pressure turbine 5 stages
Package
· Gas Generator, Power Turbine and auxiliary system mounted on a single baseplate
· weight31t
EmissionsControl
· Steam or water injection system for NOx abatement
PerformanceInfo
LM6000 43076 kWe 8707 kJ/kWh 131 Kg/s 450 °C
LM6000 44740 kW 8455 kJ/kWh 127 kg/s 456 °C

MS 7001
Overview
The MS7001EA is a single shaft heavy-duty gas turbine for power generation and industrial applications
requiringthemaximumreliabilityandavailability.
With design emphasis placed on energy efficiency, availability, performance and maintainability, the
MS7001EA is a proven technology machine with more than 500 units of its class in service.
Typical applications in addition to the 60Hz power generation service are large compressor train drives for
LNGplants.
Design Info
Compressor
Combustion
· Reverse flow, multi chamber (can-annular) combustion system (10 chambers)
Turbine
· Three stages turbine (3600 RPM)
Package
· Two baseplates configuration (gas turbine flange to flange unit and auxiliary system)
· weight121t
EmissionsControl
PerformanceInfo
MS7001EA 85100 kWe 11000 kJ/kWh 300 kg/s 537 °C
MS7001EA 81590 kW 11020 kJ/kWh 278 kg/s 546 °C

MS 9001
Overview
The MS9001E is a single shaft heavy-duty gas turbine. It was developed for generator drive service in the 50
Hertzmarket.
The MS9001E is widely applied in power generation for base, mid-range and peak load service.
Combined cycle plants based on MS9001E achieve very high efficiencies with higher availability and reliabil-
ity than conventional thermal plants.
Design Info
Compressor
Combustion
· Dualfuelcapability
Turbine
· 3 stages, first two cooled buckets
· First 2 stage nozzles cooled
Package
· Two baseplates configuration (gas turbine flange to flange unit and auxiliary system)
· weight217.5
· EmissionsControl
PerformanceInfo
MS9001E 123400 kWe 10650 kJ/kWh 412.8 kg/s 543 °C
Experiences
· 44 Units sold

GE 5 (1/2 shaft) 5,2 - 5,4 MW 26,9 %
GE 5 B 5,9 - 6,2 MW 32 %
PGT 10 10,6 MW 32,6 %
GE 10 B(1/2 shaft) 11,7 MW 33 %
PGT 16 14,2 MW 36,9 %
PGT 25 23,2 MW 37,7 %
MS 5001 26,3 MW 28,5 %
MS 5002 C-D 28,3 -32,5 MW 29,2 - 30,3%
PGT 25+ 29,9 MW 40, 3 %
MS 6001 B 42 MW 32,5 %
LM 6000 44,8 MW 41,1 %
MS 7001 EA 81,5 MW 32,7 %
MS 9001 E 123,4 MW 33,8 %
GE 2 2,0MW 25 %
TYPE MAX POWER MAX EFFiCIENCY

SECTION TH
OPERATING PRINCIPLES (Theory)

THEORY MS 5002 C Theory-3
BASEPLATE
FLANGE-TO-FLANGEUNIT
AUXILIARIES
THEORETICALOPERATINGSCHEME
Fig.Th.1showsanexampleofagasturbine(inthisspecificcase,theMS5002Cgasturbine)
withasectionalviewofthemachine.Thisfigureshowsthemaincomponents.
Fig. Th.1 - Example of a simple MS 5002 C cycle gas turbine
Themaincomponentpartsillustrated inFig.Th.1are:
• machine,generallycalledflange-to-flangeunit
• auxiliaryequipment
• baseplate
Theabovesystemsarecompletedbythesuction,exhaustandcontrolsystems, which,
liketheauxiliaryequipmentandthebaseplate,aredealtwithintherelevantchapters,
whereas hereonlydetailsabouttheirarrangementandinterfacewiththeflange-to-flange
unit(Fig.Th.1)aredescribed.
Infact,thischapterdealsexclusivelywiththeoperatingprinciplesoftheflange-to-flange
unit.

THEORY MS5002C Theory-4
TH.1 OPERATINGPRINCIPLE
Agasturbineworksinthefollowingway:
• itdrawsinairfromthesurroundingenvironment;
• itcompressesittoahigherpressure;
• itincreasestheenergylevelofthecompressedairbyaddingandburningfuelin
acombustionchamber;
• itdirectshighpressure,hightemperatureairtotheturbinesection,whichconverts
thermalenergyintomechanicalenergythatmakestheshaftrevolve; thisserves,
ontheonehand,tosupplyusefulenergytothedrivenmachine,coupledtothe
machine(LPRotor)bymeansofacouplingand,ontheotherhand,tosupply
energy necessary for air compression (HP Rotor), which takes place in a
compressorconnecteddirectlywiththeHPturbinesection;
• it exhausts low pressure, low temperature gases resulting from the above-
mentionedtransformationintotheatmosphere.
Fig.Th.2overleafshowsthepressureandtemperaturetrendsinthedifferentmachine
sectionscorrespondingtotheabove-mentionedoperatingphases.

Fig.Th.2

Fig.Th.2highlightsthefactthatcombustiontakesplaceunderalmostconstantpressure
conditions.
Unlikereciprocatingengines,compressionandexpansionareacontinuousprocess,as
happensforpowergeneration.
Onthecontrary,inareciprocatingengine(forex.,afour-stroke,Ottoengine),power
isgeneratedintheexpansionphase,likeinaturbine,butthisprocesstakesonly1/4of
thecompletecycle,whereasinagasturbineexpansiontakesplacecontinuouslyall
throughthecycle.Thesameappliestocompression.
Forthesamereason,alongwiththefactthattherearenomassesinreciprocatingmotion,
the regularity of the cycle of a gas turbine is incomparably greater than that of a
reciprocatingengine(OttoorDieselengine).
TH.2 MAIN COMPONENT PARTS OF A GAS TURBINE
Fig. Th.3 - A Sectional View of a Gas Turbine
Agasturbine(Fig.Th.3)iscomposedofthreemainsections,describedinthefollowingparagraphs.
Asconcernsdesignandconstructionfeatures,theseareextensivelydealt innextChapters.

TH.2.1 Compressor
Thecompressorisanaxial-flowtype(Fig.th.3).Theaxial-flowdesignproduces
high air flows, necessary to obtain high values of useful power with reduced
dimensions.Thisconceptwillberesumedlater,whenthemainthermodynamic
principlesoftheoperatingcycleofagasturbinearedescribed.
Acompressorconsistsofaseriesofstagesofrotatingblades,whichincreaseair
speedintermsofkineticenergy,followedalternatelybystagesofstatorblades,
whichconvertkineticenergyintohigherpressure.
Thenumberofcompressionstagesisrelatedtothestructureofthegasturbineand,
aboveall,tothepressureratiotobeobtained.
At the compressor inlet side, there are Inlet Guide Vanes (or, IGV), whose
primarypurposeistodirectair,deliveredbythesuctionsystem,towardsthefirst
stageofrotatingblades.AnotherimportantfunctionofIGVsistoensurecorrect
fluid-dynamicbehaviourofthecompressorunderdifferenttransientoperating
conditions(forexample,duringstart-upandshutdown)when,duetodifferent
runningspeedsasopposedtonormaloperatingspeed,theopeningangleofIGVs
is changed: this serves to vary the air delivery rate and to restore ideal speed
trianglesintransientphases.
Finally,incombinedcyclesandincogenerationplants,thecapabilitytochangethe
geometrical position of IGVs makes it possible to optimise turbine exhaust
temperaturesand,thus,toincreasetheefficiencyoftherecoverycyclebyvarying
theflowrateoftheairenteringthecompressor.
AtthecompressordischargesidethereareafewstagesofExitGuideVanesor
EGV, necessary to obtain maximum pressure recovery before air enters the
combustionchamber.
Thecompressorservesalsotosupplyasourceofairneededtocoolthewallsof
nozzles,bucketsandturbinedisks,whicharereachedviachannelsinsidethegas
turbine,andviaexternalconnectingpiping.Additionally,thecompressorsupplies
sealingairtobearinglabyrinthseals.

TH.2.2 CombustionSection
In the case of heavy duty gas turbines such as the one shown in Fig. Th.3, the
combustionsectionconsistsofasystemof12cannularcombustionchambers
arrangedsymmetricallyinacircumference;thesecombustorsreceiveandburn
fuelbymeansofanequalnumberofburners(oneforeachcombustionchamber).
Airenterseachchamberintheoppositedirectiontothehotinnergaspath(forthis
reason,thismethodofairdistributioniscalled"reverseflow").Thisexternalair
stream,whichflowsalongtheliners,servestocoolthem.Inaddition,theairwhich
is not used in the combustion process is used for cooling the hot gases after
combustion;infact,itisintroducedintothechambersthroughmixingholesand
coolsthegastotheoptimumturbineinlettemperature.
Thehotgaspathfromthecombustionsystemtotheturbineinletpassesthrough
transitionpieceswhichtransformtheflowsofgasfromthesinglecombustion
chambersintoacontinuousannularstreammatchingthefirststagenozzleringinlet.
Initially,thecombustionprocessisignitedbyoneormoresparkplugs.Once
ignited,combustioncontinuesunaided, aslongasfuelandcombustionairsupply
conditionsaremaintained.
Inthecaseofgasturbinesbuiltfortheaviationindustry(LM,PGT16and25
range),thecombustionsectionconsistsofasingleannularchamber,withdirect
and not reverse-flow cooling; in fact, this helped reduce outer diametral
dimensions,sinceasmallerfrontalsectionwasneededinordertoofferaslittle
resistanceaspossibletoaircraftmotion.
Forthesamereason,thiscombustionchamberdoesnotneedseparatetransition
pieces. The other operating principles are the same as those described for
cannularchambers.

TH.2.3 TurbineSection
In the case of heavy duty turbines, as shown in Fig. Th.1, the turbine section
comprisesacertainnumberofstages(inthisspecificcase,threestages),eachone
ofthemconsistingofonestatorstageandonerotorstage(buckets);inthestator
stage,hightemperatureandhighpressuregasesdeliveredbythetransitionpiece
areacceleratedanddirectedtowardsarotorstageofbucketsmountedonadisk
connectedwiththepowershaft.
Asmentionedbefore(para.Th.1),theconversionofthermalenergyandpressure
intokineticenergytakesplaceinthestatorstage.
Therotorstagecompletesthisconversion,asherekineticenergyistransformed
intoenergythatdrivestheshaft,thusgeneratingthepowerrequiredtodrivethe
compressor(internalcompressionenergy,cannotbeusedasexternallyuseful
energy)andtooperatethedrivenmachine(generator,compressor,etc.)con-
nectedtothegasturbinebymeansofacoupling.
Theenergyofgasessuppliedbythecombustionsystemcanbevariedbychanging
thedeliveryrateoffuel.Inthiswayyoucanregulatetheusefulpowervalues
neededforthetechnologicalprocessforwhichthegasturbineisthedriver.
TH.3 BRAYTONCYCLE
ThethermodynamiccycleofagasturbineisknownastheBraytoncycle.
Fig.Th.4illustratesadiagramofagasturbine.Thisdiagramisusefultounderstandthe
meaningofthethermodynamiccyclemoreeasily.
Fig.Th.4-GasTurbineOperatingDiagram
Airentersthecompressoratpoint (1),whichrepresentsatmosphericairconditions.
Theseconditionsareclassifiedaccordingtopressure,temperatureandrelativehumidity
values.
StandarddesignconditionsareconventionallyclassifiedasISOConditions,withthe

followingreferencevalues:
ISO CONDITIONS
Ambienttemperature(°C) 15
Ambientpressure(mbar) 1013
Relativehumidity(%) 60
Theairiscompressedinsidethecompressorandexitsintheconditionindicatedatpoint
(2).Duringthetransformationfrom(1)to(2),noheatistransferredtotheairbut.Air
temperature increases, due to polytropic compression, up to a value that varies
dependingongasturbinemodelandambienttemperature.
Afterleavingthecompressor,airentersthecombustionarea,practicallyunderthesame
pressureandtemperatureconditionsasatpoint(2)(exceptforlossesundergoneonthe
wayfromthecompressordischargetothecombustionchamberinlet,whichamountto
about 3 to 4% of the absolute value of discharge pressure). Fuel is injected into the
combustionchamberviaaburner,andcombustiontakesplaceat practicallyconstant
pressure.
Thetransformationbetweenpoints(2)and(3)representsnotonlycombustion. Infact,
thetemperatureoftheactualcombustionprocess,whichtakesplaceundervirtually
stechiometricconditions,reachesvalues(around2000°C)locally,inthecombustion
areanexttotheburner,whicharetoohighfortheresistanceofmaterialsdownstream.
Therefore,thefinaltemperatureofthetransformationrelativetopoint(3),islower,as
itistheresultofmixingtheprimarycombustiongaseswithcoolinganddilutionairas
describedpreviously.
Inthisregard,itisusefultogivesomedefinitionsoftemperatureatpoint(3),whichisthe
maximumcycletemperatureorfiringtemperature(seeFig.Th.5).

Fig.Th.5-Firingtemperature
Section A refers to the so-called "turbine inlet temperature", which is the average
temperatureofgasesatplaneA.
Section B refers to the so-called “firing temperature”, which is the average gas
temperatureatplane B.
SectionCreferstotheso-called“ISOfiringtemperature",whichistheaveragegas
temperatureatplaneC,calculated asafunctionoftheairandfuelflowratesviaathermal
balanceofcombustionaccordingtotheISO2314procedure.
Thedifferenceintheinterpretationoftemperaturesinsections AandBconsistsinthe
factthat,ongasturbineslikethosewhichwearedealingwithinthistrainingcourse,the
sectionBtemperaturetakesaccountofmixingwith1ststagenozzlecoolingair,which
wasnotinvolvedinthecombustionprocess,butmixeswithburntgasesaftercoolingthe
surfaceofthenozzle.
AccordingtotheNuovoPignone -GeneralElectricstandard,thetemperaturethatbest
representspoint (3)istheoneinsectionB.
Thefollowingtransformation,comprisedbetweenpoints(3)and(4),representsthe

expansionofgasesthroughtheturbinesection,which,asmentionedbefore,converts
thermalenergyandpressureintokineticenergyand,bymeansofshaftrotation,intowork
usedforcompression(internal,notusable)andexternalusefulwork,throughcoupling
withadrivenmachine.
Over50%oftheenergydevelopedbyexpansioninthegasturbineisrequiredforthe
compressionbytheaxialcompressor.
Downstreamofsection(4),gasesareexhaustedintotheatmosphere.
Thethermodynamicrepresentationoftheeventsdescribedsofaris visibleinFig.2.6
(pressurediagrams-volumeP-Vandtemperature-entropyT-S).
Fig. Th.6 - Brayton Cycle
Inthecycleillustratedintheabovefigure,the 4pointscorrespondtothesamepoints
describedbefore.
Inparticular,notethecompressionandexpansiontransformations,obviouslytheseare
notisentropic.
Inthisrespect,pleaserememberthat:
thespecificcompressionworkWc
,from(1)to(2),isexpressedwithgoodapproxi-
mationbythefollowingequation:
Wc = Cpm(T2-T1) • (T2-T1) (kJ/kginletair)
the specificexpansionworkWt
,from (3)through(4),isexpressedby:
Wt = Cpm(T3-T4) • (T3-T4) (kJ/kggas.)
Heat Q1
,suppliedtothecombustionchamberfrom (2) to (3),isexpressedby:
Q1 = Cpm(T3-T2) • (T3-T2) (kJ/kggas.)
Thegasturbinecycle"closes"ideallywiththetransformationfrom(4)to(1),which

correspondstothecoolingofexhaustgases,byremovedofheatQ2
bytheatmosphere,
asthoughthelatterwerearefrigerantofinfinitecapability.
Thethermodynamicequationthatdescribescoolingofexhaustgasesisthefollowing:
Q2 = Cpm(T4-T1) • (T4-T1) (kJ/kggas.)
Thevariousvaluesfor Cpm
,expressedintheprecedingratios,representtheaverage
specificheatatconstantpressurebetweentheextremetemperaturevaluesintheinterval
examined.
Foramorerigorousevaluation,itwouldbenecessarytoproceedbymeansofintegral
calculation.
Once Q1
, Q2
, Wc
and Wt
, are known, you can obtain the values for the following
significantparameters:
Thermodynamic efficiency h = (Q1
- Q2
)/Q1
Thisequationtellusthat,byparityofheatQ1
,introducedintothecombustionchamber
byfuel,efficiencywillincreaseasheatQ2
,“dissipated”intotheatmospheredecreases.
WewillseeinChap.8howtorecoverthisheatpartiallyincombinedcyclesandinthe
regenerativecycle.
UsefulworkNu
suppliedtothedrivenmachine=Ggas
Wt
-Garia
Wc
Inthelatterequation,Ggas
andGair
representrespectivelytheweightflowsofturbineinlet
gas,andcompressorinletairnecessarytopassfromspecifictoglobalvalues.
Suchtypesofsingleshaftturbinesaresuitablefordrivingmachinesthatrunatconstant
speed,suchasalternatorsand,forthisreason,areusedtypicallyinthegenerationof
electricenergy.
Suchtypesofsingleshaftturbinesaresuitablefordrivingmachinesthatrunatconstant
speed,suchasalternatorsand,forthisreason,areusedtypicallyinthegenerationof
electricenergy.
Inapplications,inwhichpowerisregulated by variationof thespeedofthedriven
machine,two-shaftgasturbines(asMS5002C)areusuallyemployed (seediagram
inFig.Th.7);inthiscase,theturbineisdividedintotwomechanicallyseparatesections:
• A high pressure section, which runs at constant speed within a wide range of
powers,anddrivesexclusivelyanaxialcompressor.
• Alowpressuresection,connectedwiththedrivenmachineviaacoupling;this
sectioncanvaryitsspeedofrotationindependentbyfromthehighpressureturbine
section.

Thisconfiguration,withtheadditionofotherelementswhichwillbedescribedinoneof
nextchapters,servestoregulatethedrivenmachinespeedwithouttheneedtovarythe
speedoftheaxialcompressor;thus,thelattermaycontinuetorunatitsdesignspeed,
withoptimalefficiency.
Fig.Th.7-TwoShaftGasTurbineDiagram
Theequationsdescribedsofarapplyingeneraltoalltypesofturbine.
TheclassicalconceptsofthermodynamicsallowacorrectevaluationoftheBrayton
cycle and influence of parameters such as pressures, temperatures, specific heats,
polytropicexponents,etc.
AdiagraminFig.Th.8expressestheconnectionsamongthefollowingparameters:
• Firing temperature T3
(for MS 5002 C T3
= 966°C)*
• Pressure ratio (for MS 5002 C Pressure Ratio = 8,8)*
• Thermalefficiency(forMS5002C =29,23%)*
• Specific power (for MS 5002 C Specific Power = 230,41 kW/(kg/sec.))*
*ISOCondition
HP LP

Fig.Th.8-Relationsbetweensignificantthermodynamicquantities
Thisdiagramindicatesthat:
a) UnderequaltemperatureT3
,maximumefficiencyisreachedbyincreasingthe
presssure ratio. The maximum efficiency value does not correspond to the
maximumspecificpower.
b) Thehighertheincreaseintheratio,thegreaterthebenefitprovidedbyincreased
firingtemperatureT3
forspecificpowerandefficiencyvalues.
However,itisnotpossibletoexceedcertainvaluesforT3
,becauseof limitations
imposedbytheresistanceofthematerialscurrentlyavailable. Theincreasein
temperatureT3
thereforerepresentsaveryimportantparameterthatrequires
considerableongoingresearchasfarasregardsmaterials,bladecoolingtechnol-
ogy,etc.,inordertoachieveareliableandefficientproductcapabletomeetever
growingdemandsbythemarket.
c) Specificpowerisimportantbecauseahigherspecificpowermeansagasturbine
withmorereduceddimensions,thoughofequalpoweroutput.
d) Efficiencyisimportant,becausethehighertheefficiency,thelowertheconsump-
tionandoperatingcosts.

TH.4 INFLUENCE OF EXTERNAL FACTORS ON GAS TURBINE PERFOR-
MANCE
Agasturbineusesatmosphericair,therefore,itsperformanceisgreatlyaffectedbyall
factorsthatinfluencetheweightflowrateofairdeliveredtothecompressor.
Thesefactorsare:
• Temperature
• Pressure
• Relativehumidity
Inthisregard,weremindyouthatreferenceconditionsforthethreeabove-mentioned
factorsare,byconvention,ISOstandards(para.TH.3).
As the compressor inlet temperature increases, the specific compression work in-
creases,whiletheweightflowrateoftheairdecreases(becauseofadecreaseinspecific
weightg).Consequently,theturbineefficiencyandusefulwork(and,therefore,power)
decrease.Iftemperaturedecreases,thereverseoccurs.
Thistiebetweencompressorinlettemperatureandpowerandefficiencyvariesfrom
turbinetoturbine,accordingtocycleparameters,compressionandexpansionefficien-
ciesandairflowrate.
Fig.Th.9showsanexampleofhowpower,heatrateandexhaustgasflowareaffected
byambienttemperature.
Fig.Th.9-Influenceofambienttemperatureonturbineperformance
EXHAUSTGASFLOW
AMBIENT
TEMPERATURE(°C)

Heatrate,dimensionallyrepresentedinfigureTh.9,istheinverseofefficiency,inthatit
indicatestheratiobetweenthermalenergy,resultingfromthecombustionprocess,and
mechanicalenergy,obtainedonthepowershaft(oratthegeneratorterminals,ifwe
considertheperformanceofaloadgearandgenerator).
Tosummarise,andcallinsQ1
theenergyresultingfromcombustionand Nu
theexternal
usefulwork,theHeatRateisdefinedas:
HR = Q1/Nu
andisgenerallyexpressedas kJ/kWh.
IftheatmosphericpressuredecreasesincomparisonwiththeISOreferencepressure,
theweightflowrateofairdecreases(becauseofareductioninitsspecificweight)and
usefulpowerisproportionallyreducedbeingproportionaltotheweightflowrateofgas.
Onthecontrary,theotherparametersofthethermodynamiccycle(HR,etc.)arenot
affected.
Fig.Th.10showsgasturbineusefulpowerversusinstallationaltitude.
Fig.Th.10
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
PRESSURE
PRESSURE
PRESSURE
PRESSURE
PRESSURE CORRECTION
CORRECTION
CORRECTION
CORRECTION
CORRECTION
FACTOR
FACTOR
FACTOR
FACTOR
FACTOR
CORRECTION
CORRECTION
CORRECTION
CORRECTION
CORRECTION
FACTOR
FACTOR
FACTOR
FACTOR
FACTOR
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
ATMOSPHERIC
PRESSURE
PRESSURE
PRESSURE
PRESSURE
PRESSURE
ALTITUDE - 1000 FEET

Relativehumidityinfluencesthespecificweightofcompressorinletair.Infact,humidair
islessdensethandryair,soiftherelativehumidityincreases,thepoweroutputdecreases
andheatrate(HR)increases(Fig.Th.11).
Inthepast,suchaneffectusedtobeneglected.Nowadays,asevermorepowerfulgas
turbinesaremade andhumidityisaddedintheformofwaterorsteamtoreduceNOx
,
thiseffectmustbetakenintoconsideration.
Fig.Th.11
TH.5 INFLUENCE OF INTERNAL FACTORS ON GAS TURBINE PERFOR-
MANCE
Addedtothethree“external”factorsdescribedintheprecedingparagraph,thereare
otherfactorswhichnotablyaffecttheperformanceofagasturbine.Thesemaybecalled
“internal”factors,becausetheyarerelatedtotheauxiliarysystemsofthegasturbine.
Theyarethefollowing:
• Pressurelossesinthecompressorinletsection
• Pressurelossesintheturbineexhaustsystem
• Fueltype
• Airextractionfromtheaxialcompressor
• Steaminjection
• Waterinjection
• Evaporativecooling

Pressurelossesinthecompressorinletsection
Pressurelossesarecausedbythegasturbineinletsystem,composedofanairfitter,a
silencer,anelbow,pipesectionvariations,etc.,installedupstreamofthecompressor
suctionflange.Whenairflowsthroughthissystem,itissubjectedtofriction,which
reducesitspressureandspecificweight.Theselossescauseareductioninusefulpower
andanincreaseheatrate,asmentionedpreviouslyduethecaseoftheinfluenceexerted
byambientpressure.
Pressurelossesintheturbineexhaustsystem
Thesearecausedbythegasturbineexhaustsystem,composedofoneormoresilencers,
anelbow,arecoveryboiler(incaseofcombinedcyclesorcogeneration),diverters,
diffusers,etc.,throughwhichexhaustgasesareexpelledintotheatmosphere.
Exhaust gases flowing through this system are subjected to friction losses, which
increasesthevalueofbackpressureasopposedtothevalueofexternal,atmospheric
pressure.Theselossesreducetheamountofturbineexpansion,asthelatterterminates
oneisobarhigherthanthereferenceone,whichresultsinreduced usefulpowerand
increasedheatrate.
TableTh.1givestypicalvaluesshowinghowperformanceisaffectedbyinletandexhaust
pressure losses. For the reasons explained above, these affects are proportional to
pressurelosses.
TABLETh.1 EFFECTSOFPRESSURELOSSES
Every100mmH2O atsuction: Every 100 mm H2O at exhaust :
1.6%powerloss 0.6% power loss
0.6%increaseinHeatRate 0.6 % increase in Heat Rate
1°Cincreaseinexhausttemperature 1°Cincreaseinexhausttemperature
Influenceofthetypeoffuel
Bestperformanceisachievedifnaturalgasratherthandieseloilisused.Infact,output
powerunderbaseloadandwithotherconditions(environmental,pressuredrops,etc.)
being the same is about 2% greater and Heat Rate is between 0.7 and 1% lower,
dependingongasturbinemodel.
Thesedifferenceswillbecomeallthemoreremarkableifwecompareperformances
obtainedwithnaturalgasandwithprogressively "heavier"fueltypes,suchasresiduals,
BunkerC,etc.
Thisbehaviorisduetothehigherheatingvalueofproductsoriginatedbythecombustion
ofnaturalgas,asthelatterhasahighercontentofwatervapour, resultingfromahigher
ratiobetweenhydrogenandcarbon,whichistypicalofmethane,themaincomponent
ofnaturalgas.

Gaseousfuelswithalowerheatingvaluethannaturalgas(commonlycalledlow-Btu
gases)cangreatlyinfluencetheperformanceofagasturbine.
In fact, if the heating value decreases (kJ/Nm3
), the weight flow rate of fuel to the
combustion chamber must increase to provide the necessary amount of energy
(kJ/h).
Thisadditioninflowofthefluid,whichisnotcompressedbythecompressor,creates
anincreaseinpower(seethedefinitionofusefulworkinpara.Th.3)andareduction
inheadrate.
Inthiscase,thepowerabsorbedbythecompressorissubstantiallyunchange.
However,inthecaseofcombustionoflow-Btugases,thefollowingsideeffectsmustbe
takenintoconsideration:
• An increase in the turbine flow rate increases the compression ratio in the
compressor,whichmustnotcometoonearthesurgelimit.
• Anincreaseinthefuelflowrateoftenrequireslargerdiameterpipingandcontrol
valves(raisingcosts).Thiseffectisallthemoreconspicuousifalsoalsothegas
temperature and, therefore, specific volume are higher (for example, gases
producedfromcoalgasification).
• Gaseswithalowheatingvaluearefrequentlyenoughsaturatedwithwatervapour
upstreamofthegasturbinecombustionsystem.Thisincreasestheheattransfer
ratesraisingthemetaltemperatureofthehotpartsoftheturbine.
Airextractionfromtheaxialcompressor
Insomegasturbineapplications(chemicalprocesses,pipeblowingduring commission-
ing,etc.)itmaynecessarytoextractcompressedairfromthecompressordischarge.
Asageneralrule,andunlessprescribedotherwiseinthecaseofaeroderivativemachines,
it is possible to bleed as much as 5% of the compressor flow without making any
modificationtotheturbinedesign.
Itispossibletoachieveextractionvaluesrangingbetween6and20%,dependingonthe
machineandcombustionchamberconfiguration,ifalterationsaremadetocasings,piping
andthecontrolsystem.
Fig.Th.12showshowpercentagesofairextractioninfluenceoutputpowerandheatrate,
takingintoconsiderationalsoambienttemperature.

Fig.Th.12
Steaminjectionandwaterinjection
Steamorwaterinjectionmayhavethefollowingtwopurposes:
• areductioninnitrogenoxide(NOx)level.
• anincreaseinoutputpower.
Reducingthenitrogenoxide(NOx)level
The method of steam or water injection was introduced in the early 70s to limit and
controlthepresenceofnitrogenoxidesorNOX.
Injectionisusuallyperformedinthecombustionchambercaparea.Theinjectionsystem
limitsthemaximumamountofinjectablesteamorwater,inordertosafeguardstability
andcontinuityinthecombustionprocess.However,theamountofsteamandwater
injectedissufficienttoachieveconsiderableNOxabatementlevels.
Accordingtotheamountofsteamorwaterinjectedintothecombustionchamber,which
theturbinecontrolsystemautomaticallymonitorsinrelationtotheNOxleveldesired,
outputpowerwillincreaseasaresultoftheincreaseinmassflowthroughthegasturbine.
Inthecaseofsteaminjection,theHeatRatewillalsodecreaseforthesamereasonsthat
applytolowheatingvaluefuelgases.
Onthecontrary,thelatteradvantagedoesnotexistinthecaseofwaterinjection,asit
requiresagreaterquantityoffueltobevaporizedtotheconditionsnecessaryforinjection
intothecombustionchamber.
HEAT
RATE
(%)
HEAT
RATE
(%)
HEAT
RATE
(%)
HEAT
RATE
(%)
HEAT
RATE
(%)
POWER
(%)
POWER
(%)
POWER
(%)
POWER
(%)
POWER
(%)

Inpeakdutyconditions,withamaximumof1250hours/year,itispossibletoincrease
thewaterflowratethroughthecombustionchambercapareainordertoincreasethe
gasturbinepoweroutput.Obviously,thiscallsfor shortermaintenanceintervals.
Asconcernsthemaximumwaterflowratesandmaintenanceprocedures,thesemustbe
evaluatedcasebycase,dependingonthemachinemodelandits combustionsystem.
Poweraugmentation
Steaminjectionforpoweraugmentationhasbeenavailableandwarrantedbyover30
years'experience.
Unlikewaterinjection,steamisinjectedintothecompressordischargecasing,thus
eliminatingalllimitationsimposedinordertosafeguardstabilityinthecombustion
process. For this reason, the maximum amount of injectable steam is limited to
percentagevaluesoftheweightflowrateofcompressorsuctionair.
Steammustbesuperheated,andtheremustbeatleast25°Cdifferencewith respect
tothecompressordischargetemperature;steamsupplylimitpressuremustbeatleast
4bar(g)greaterthanmaximumpressureinthecombustionchamber.
Inthecaseof steamorwaterinjection,theamountofsteaminjected inpartialload
conditionsmustbeequaltotheamountrequiredforNOxabatement.Oncethebaseload
valueisreached,thecontrolsystemgivestheOKtoinject theadditionalsteam needed
toincreasetheturbineoutputpower.
Fig.Th.13showsthetypical effectsofsteaminjectionontheoutputpowerofagas
turbine(inthiscase,anMS5002gasturbine)asafunctionofambienttemperature.

Fig. Th.13 - Effects of steam injection on output power
(MS5002GasTurbine)

COALESCER/DEMISTER
SUMP TANK
CELLE AD EVAPORAZIONE
COLLETTORE H2O
POMPA DI CIRCOLAZIONE H2O
ARIA REFRIGERATA
VERSO IL FILTRO
DELL ARIA
ARIA CALDA AMBIENTE
Evaporativecooling
The curves in fig. Th.9 clearly show how power and efficiency increase as the
compressorinlettemperaturedecreases.
Thelattercanbereducedartificiallybyusinganevaporativecoolerlocatedupstreamof
thesuctionfilter.
Water,separatedintodropsorintheformofaliquidfilm,coolstheairbyevaporating
inthecoolerasitflowsintheoppositedirection,thusoriginatinganadiabatic-isoenthalpic
exchange(seefig.Th.14).
Fig.Th.14Evaporativecooler
In order to prevent water from being drawn towards the compressor and fouling it,
downstreamofthecoolerthereareoneormorestagesofdropseparators(demisters),
whichseparatebyinertiaanywaterdropsthatmightbeentraineddownstreamofthe
coolerbytheflowofairingestedbytheturbine.
Fig.Th.15showstheeffectsofevaporativecoolingonthegasturbineoutputpowerand
heatrate.
Ascanbenoted,benefitsincreaseasrelativehumiditydecreasesandambienttempera-
tureincreases.
Unfortunately,theaboverequirementsaremetinenvironments(forexample,deserts),
wheretheamountofwaterneededbythecoolerisnotalwaysavailable.
COOLEDAIR
TOWARDAIR
FILTER
AMBIENTHOTAIR
EVAPORATIONCELLS
H20HEADER
COALESCER/DEMISTER
SUMPTANK
H2
OCIRCULATINGPUMP

Fig.Th.15EffectsofEvaporativeCoolingonPerformance
Inletchilling
Inenvironmentswithahighdegreeofaveragerelativehumidity(higherthan60%)and
withoutextremeambienttemperatures,itisadvisabletocoolairwithadifferentmethod,
commonly called "inlet chilling"; according to this method, air is cooled during a
refrigerating cycle (based generally on absorption) carried out in a closed loop
arrangement.Inthisway,therestrictionsimposedbyrelativehumidityandbyambient
temperature, described in the preceding system, can be eliminated. The minimum
temperaturereachedbyairattheendofthecoolingprocessisstrictlydependenton the
capabilityoftherefrigeratingcycletoproducecoldliquidandontheefficiencyofthe
thermalexchangethattakesplaceinthewater-airexchanger.
FigureTh.16showsanoperatingdiagramofthissystem(inthisexample,steamisused
fortheabsorptioncycle),composedofachiller,waterconnectingpipingandawater-
airexchanger,installeddownstreamofthegasturbineinletfilter.Asinevaporative
cooling,alsointhiscaseitisnecessarytoinstallacoalescer/demisterdownstreamofthe
system,inordertopreventmoisturefromreachingthecompressorinletsection.

Fig. 2.16 Air chilling / cooling system, based on absorption
FigureTh.17showsacomparisonbetweenthecoolingpowersofthetwosystems.
Fig.Th.17Comparisonpsychometricchart
DRENAGGIO
CHILLER
CAMERA
FILTRI
SCAMBIATORE
DEMISTER/COALESCER
ARIA AMBIENTE
ARIA FREDDA VERSO
IL COMPRESSORE
INGRESSO VAPORE
ALLA TORRE DI RAFFREDDAMENTO
INGRESSO ACQUA FREDDA
RITORNO ACQUA DA RAFFREDDARE
% RH const. lines
Saturation line
constant moisture content line
Kgwater/Kgair
a
b
c
d
Ta
Tc Td
constant enthalpy line
PSYCHROMETRIC
CHART
Tb
DEMISTER/COALESCER
COOLEDAIR
TOCOMPRESSOR
DRAIN
CHILLER
STEAMINLET
TOCOOLING
TOWER
FILTER
PLENUM
AMBIENTAIR
HEATEXCHANGER
COOLINGWATERINLET

Line a-drepresentsaircoolinginthecaseofevaporativecooling. Asmentionedbefore,
thislinefollowstheconstantenthalpyline,resultinginaprogressiveincreaseinrelative
humidity.
Therestrictionimposedbythiscoolingmethodconsistsinthefactthatthereremainsa
minimumdistancefromthesaturationcurve,compatiblywithrealisticexchangesurfaces,
consideredfromthepointofviewofconstruction.Normalvaluesindicatearound90%
relativehumidity,thatis,therestillremainsa10%marginbeforethesaturationlineis
reached.
Undertheseconditions,thefinalairtemperatureisequalto Td.
Inthecaseofthechillingprocess,thecoolinglinehasaconstantmoisturecontent along
segmenta-b.Ifthepotentialoftherefrigeratingcycleandtheefficiencyoftheexchanger
allowit, coolingcanreachthesaturationlineandfollowitalongsegment b-c,inwhich
heatisremovedtoformcondensate(H2
O).Inthissecondsegment,thereisasmaller
temperaturereduction,becausemostofthecoolingenergyservesforthecondensing
processandonlyasmallpartofitparticipatesinloweringtemperature.
Inthechillingsystem,thefinalairtemperaturewillbeequaltoTborTc,dependingon
totheselecteddegreeofcooling.

INSTRUCTION , OPERATION AND
MAINTENANCE MANUAL
(MS5002C)
Volume I
Gas Turbine Description & Operation
NUOVO PIGNONE JOB : 160.5876
CUSTOMER : ENTERPROSE S.A.
N.P. SERIAL NUMBER : G07621
SERVICE : TURBOCOMPRESSION
PLANT LOCATION : ALGERIA
MANUFACTURER : GEPS Oil & Gas
Nuovo Pignone
Via F. Matteucci, 2
50127 Florence - Italy
Telephone (055) 423211
Telefax (055) 4232800
09-06-E 160.5876 P. 1-1
MOD. INPR/SVIL/ P.F. 12/00

INSTRUCTIONS MANUAL
INSTRUCTIONS MANUAL
Status and description of the revisions
Status and description of the revisions
Stato di revisione
Revision Status
Data
Date
Eseguito
Prepared
Controllato
Checked
Approvato
Approved
Descrizione della revisione
Description of the revisions
00 09-06 G.D.S. ISSUED
© 2001 Nuovo Pignone S.p.A., tutti i diritti riservati
NUOVO PIGNONE PROPRIETARY INFORMATION
Questo documento include informazioni confidenziali e di proprietà di Nuovo Pignone e non può essere riprodotto, copiato, o
fornito a terza parte senza il preventivo consenso scritto di Nuovo Pignone.
I destinatari accettano di prendere ogni ragionevole precauzione per proteggere tali informationi da uso non autorizzato o
dalla loro divulgazione.
© 2001 Nuovo Pignone S.p.A., all rights reserved
NUOVO PIGNONE PROPRIETARY INFORMATION
This document includes proprietary and confidential information of Nuovo Pignone and may not be reproduced, copied, or
furnished to third parties without the prior written consent of Nuovo Pignone.
Recipient agrees to take reasonable steps to protect such information from unauthorized use or disclosure.
09-06-E 160.5876 P. 1-1

After Sales Service
09-01-E After-Sales Service P. 1/2
MOD. INPR/SVIL/D.L./P.F. 06/01
Introduction to Nuovo Pignone after-sales service
Nuovo Pignone organization is structured in such a way as to guarantee a comprehensive and
effective after-sales service for its machinery.
Here is briefly described the organization of the company, based on its experience as a
manufacturer and on a continuous effort to meet customers needs.
Being aware of the importance of maintenance in all operational activities, Nuovo Pignone deals
with its various aspects from the design stage, through:
- the use of design criteria that enhance maintainability,
- the continuos research of innovative solutions to improve availability,
- the selection of components and advanced technologies to enhance equipment maintenance,
- the inspection procedures and topics, to be used in connection with a detailed schedule of
maintenance operations,
- the choice of the spare parts to be kept in stock, optimizing investment cost vs plant
downtime.
In late years Nuovo Pignone after-sales service has also been brought up-to-date to guarantee the
best support to its customers. In more details:
- worldwide,
where Nuovo Pignone has been operating for tens of years, the structure consists of a service
network which is the natural expansion of the "Customer Service Division" in Florence.
There are localized Service Units and authorized Service Shops at strategic points of the world, to
cover areas where plants with Nuovo Pignone machinery are located.
- in Florence, ( Headquarters)
specialized depts. which are active from the receipt of the enquiry, to the issue of the offer and, in
case of an order, to the management of all activities connected with the job, up to its completion.
This organization, available for all customers, ensures a qualified interface to refer to for any
requirements in connection with operation/maintenance of machinery.
The names and address for localized Service Units and authorized Service Shops are available at
GE POWER SYSTEM WEB SITE (URL: http://www.gepower.com) selecting from its home
page the following choices: Business sites/GE Nuovo Pignone/Sales Organization
(complete URL:
http://www.gepower.com/geoilandgas/oil_gasbrands/nuovo_pignone/sales_org.html) .
In the section “Service” of this page are available the names and addresses of localized Service
Units divided into geographical areas.
In the above indicated web site, in the section “New Units” are available the names and addresses
of the Branch Offices Abroad divided into geographical areas.
Nuovo Pignone has been managing for many years special after sales "Support Packages". These
packages typically include:

After Sales Service
09-01-E After-Sales Service P. 2/2
MOD. INPR/SVIL/D.L./P.F. 06/01
- diagnostic analysis of machines in operation
- consultancy in scheduling maintenance based on operational requirements
- field maintenance
- refurbishing of worn components
- original spare parts supplies
- technical expertise in updating machines
Product engineering departments are staffed with experts in analysing machinery operating data,
who provide users with technical consulting services aimed at optimizing use of equipment. The
entire service organization guarantees users get the most suitable maintenance to restore original
design conditions and the total information relevant to all technological innovations introduced in
Nuovo Pignone's products as applicable to the installed machinery.
Full flexibility allows us to adapt each maintenance contract upon User's needs.Service Agreements
in force today, range from "On call" basis to "Global Service"

Job: 160.5876 VOL. I
I N D E X
1. CONTENTS 1-2
1.1 INTRODUCTION 1-2
1.1.2 General 1-2
1.1.3 Gas turbine 1-2
1.1.4 Principals of Gas Turbine Operation 1-3
1.2 EQUIPMENT DATA SUMMARY 1-4
1.3 PERFORMANCE CURVE (SOM6609239) 1-8
1.4 TURBINE TWO SHAFT DIAGRAM (SYMPLE CYCLE) 1-9
2. GAS TURBINE DESCRIPTION 2-2
2.1 GENERAL 2-2
2.1.1 Detail orientation 2-2
2.2 TURBINE BASE 2-2
2.3 TURBINE SUPPORTS 2-3
2.3.1 Gib key and guide block 2-3
2.4 ACCESSORY BASE AND SUPPORTS 2-4
3. COMPRESSOR SECTION 3-2
3.1 GENERAL 3-2
3.2 COMPRESSOR ROTOR 3-2
3.3 COMPRESSOR STATOR 3-3
3.4 INLET CASING 3-3
3.5 COMPRESSOR CASING 3-4
3.6 COMPRESSOR DISCHARGE CASING 3-4
4. COMBUSTION SECTION 4-2
4.1 GENERAL 4-2
4.2 COMBUSTION WRAPPER (SHORT) 4-2
4.3 COMBUSTION CHAMBERS 4-3
4.3.1 Spark plugs 4-3
4.3.2 Ultraviolet flame detectors 4-4
4.3.3 Fuel nozzles 4-5
4.3.4 Crossfire tubes 4-5
06-06-E 160.5876 P. 1-5

Job: 160.5876 VOL. I
I N D E X
5. TURBINE SECTION 5-2
5.1 GENERAL 5-2
5.2 TURBINE STATOR 5-2
5.3 FIRST-STAGE NOZZLE 5-3
5.4 SECOND-STAGE NOZZLE 5-3
5.5 DIAPHRAGM ASSEMBLY 5-4
5.6 TURBINE ROTOR AND WHEELS 5-4
5.6.1 Turbine buckets 5-5
6. BEARINGS 6-2
6.1 GENERAL 6-2
6.2 LUBRICATION 6-3
6.3 G.E. BEARING PUBLICATION 6-4
7. GEARS 7-2
7.1 ACCESSORY GEAR ASSEMBLY 7-2
8. COUPLING 7-2
8.1 GENERAL 8-2
8.2 CONTINUOSLY LUBRICATED ACCESSORY GEAR COUPLING 8-3
8.3 CONTINUOUSLY-LUBRICATED LOAD COUPLING 8-3
8.4 LUBRICATION 8-3
8.5 TOOTHWEAR 8-4
9. INLET AND EXHAUST SYSTEM 9-2
9.1 GENERAL 9-2
9.2 AIR INLET 9-2
9.3 INLET COMPARTMENT 9-3
9.4 INLET DUCTING 9-3
9.5 EXHAUST SYSTEM 9-4
9.6 EXHAUST PLENUM 9-4
9.7 VENTILATION SYSTEM 9-4
9.7.1 General 9-4
9.7.2 Gas Detection System 9-5
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Job: 160.5876 VOL. I
I N D E X
10. STARTING SYSTEM (ELECTRIC STARTING MOTOR) 10-2
10.1 GENERAL 10-2
10.2 FUNCTIONAL DESCRIPTION 10-2
10.3 STARTUP FUNCTIONS AND SEQUENCES 10-3
10.4 TORQUE CONVERTER ASSEMBLY 10-3
10.5 HYDRAULIC RATCHET SYSTEM 10-4
10.6 RATCHET SYSTEM OPERATION 10-4
10.7 STARTING JAW CLUTCH 10-5
11. GAS FUEL SYSTEM 11-2
11.1 GENERAL 11-2
11.3 GAS STOP/RATIO AND CONTROL VALVE (SRV-1-GCV-1) 11-4
11.4 GAS STRAINERS 11-4
11.5 PROTECTION DEVICES 11-5
11.5.1 Fuel Gas Vent Valve (20 VG-1) 11-5
11.5.2 Low Fuel Gas Pressure Switch (63FG-1) 11-5
11.5.3 Pressure Transmitter (96FG) 11-5
11.5.4 Pressure Gauges 11-5
11.6 FUEL GAS TREATMENT AND CYCLONE SKIDS 11-6
12. LUBE OIL SYSTEM 12-2
12.1 GENERAL 12-2
12.3 LUBE OIL TANK AND PIPING 12-3
12.4 LUBE OIL PUMPS 12-4
12.5 MAIN LUBE OIL PUMP (ACCESSORY GEAR DRIVEN) 12-4
12.6 AUXILIARY LUBE OIL PUMP (AC MOTOR DRIVEN) 12-4
12.7 EMERGENCY LUBE OIL PUMP (DC MOTOR DRIVEN) 12-5
12.7.1 Cooldown Period 12-6
12.8 VALVES 12-6
12.8.1 Check valves 12-6
12.8.2 Test valve - low lube oil pressure - auxiliary pump start 12-7
12.8.3 Test valve - low lube oil pressure/emergency pump start 12-7
12.8.4 Regulating valve VPR-2 - lube oil header pressure regulating 12-8
12.9 LUBE OIL TEMPERATURE CONTROL 12-8
12.9.1 Standby heaters 12-8
12.10OIL FILTERS 12-9
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Job: 160.5876 VOL. I
I N D E X
12.10.1 Main Oil Filter 12-9
12.11PRESSURE AND TEMPERATURE PROTECTIVE DEVICES 12-10
12.11.1 Oil level gauge and alarm 12-10
12.11.2 Low lube oil pressure alarm switches, 63QA-1 and -2 12-11
12.11.3 High lube oil temperature alarm and trip switches 12-11
12.12HYDROCARBON BASE LUBRICATING OIL
RECOMMENDATIONS FOR GAS TURBINE (SOM 17366/4) 12-12
12.13LUBE OIL COOLER 12-13
12.13.1 Temperature regulating valve (VTR-1) 12-13
12.14OIL VAPOUR SEPARATOR 12-13
13. HYDRAULIC SUPPLY SYSTEM 13-2
13.1 GENERAL 13-2
14. CONTROL AND TRIP OIL SYSTEM 14-2
14.1 GENERAL 14-2
14.3 SECOND-STAGE NOZZLE CONTROL ASSEMBLY 14-3
14.4 INLET GUIDE VANE CONTROL ASSEMBLY 14-5
15. COOLING AND SEALING AIR SYSTEM 15-2
15.1 GENERAL 15-2
15.2 TENTH-STAGE EXTRACTION AIR 15-2
15.3 COMPRESSOR HIGH PRESSURE SEAL LEAKAGE AIR 15-3
15.4 AIR EXTRACTION SYSTEM FOR STARTUP AND
SHUTDOWN COMPRESSOR PULSATION PROTECTION 15-3
16. FIRE PROTECTION SYSTEM (CO2) 16-2
16.1 GENERAL 16-2
16.3 FIRE FIGHTING SYSTEM OPERATION 16-3
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Job: 160.5876 VOL. I
I N D E X
17. OPERATION 17-2
17.1 OPERATOR RESPONSIBILITY 17-2
17.2 GENERAL OPERATING PRECAUTIONS 17-2
17.2.1 Temperature Limits 17-2
17.2.2 Pressure Limits 17-4
17.2.3 Vibration Limits 17-4
17.2.4 Load Limit 17-5
17.2.5 Combustion System Operating Precautions 17-6
17.2.6 Cooldown/Shutdown Precautions 17-7
17.3 PREPARATIONS FOR NORMAL LOAD OPERATION 17-8
17.4 STANDBY POWER REQUIREMENTS 17-9
17.5 CHECKS PRIOR TO OPERATION 17-9
17.6 CHECKS DURING START UP AND INITIAL OPERATION 17-11
17.6.1 Crank 17-11
17.6.2 Fire 17-11
17.6.3 Automatic, Manual 17-12
17.7 ROUTINE CHECKS DURING NORMAL OPERATION 17-14
06-06-E 160.5876 P. 5-5

INDEX
1. CONTENTS......................................................................................................................2
1.1 INTRODUCTION .....................................................................................................2
1.1.2 General ................................................................................................................2
1.1.3 Gas turbine...........................................................................................................2
1.1.4 Principals of Gas Turbine Operation...................................................................3
1.2 EQUIPMENT DATA SUMMARY..........................................................................4
1.3 PERFORMANCE CURVE (SOM6609239)............................................................8
1.4 TURBINE TWO SHAFT DIAGRAM (SYMPLE CYCLE)..................................9
06-06-E 160.5876 P. 1-9

1. CONTENTS
1.1 INTRODUCTION
1.1.2 General
The Model Series 5002 two-shaft, mechanical drive gas turbine is a ma-
chine that is used to drive a centrifugal load compressor.
Attached to the forward end of the gas turbine base, is an air inlet com-
partment and ducting which contains self-cleaning inlet filtration system,
that attenuates the high frequency noise, and an inertial air separator,
which removes foreign particles before the air enters the turbine.
1.1.3 Gas turbine
The gas turbine portion of the mechanical drive gas turbine unit, is that
part, exclusive of control and protection devices, in which fuel and air are
used to produce shaft horse-power. The air compressor rotor is of 16
stages.
The gas turbine has two mechanically independent turbine wheels. The
first-stage, or high pressure, turbine wheel drives the compressor rotor
and the shaft driven accessories. The second stage, or low pressure, tur-
bine wheel drives the load compressor. The purpose of unconnected tur-
bine wheel is to allow the two wheels to operate at different speeds to
meet the varying load requirements of the centrifugal compressor.
The gas turbine incorporates a four-bearing design that utilizes pressure
lubricated eliptical and tilting pad journal bearing. Bearing Nos. 1 and 2
support the compressor rotor and first-stage turbine wheel. Bearing Nos.
3 and 4 support the second-stage turbine wheel and the load shaft. The
four-bearing design assures that the critical speeds of the rotating parts
are higher than the turbine operating speed range. It also permits rapid
starting, loading and stopping.
06-06-E 160.5876 P. 2-9

In addition, it allows the turbine wheel buckets and rotor blades to be
maintained at close clearances to obtain component efficiency and higher
output.
Both turbine wheels have precision-cast, long-shank buckets. This inno-
vation effectively shields the wheel rims and bucket bases from the high
temperature of the main gas stream. The turbine wheels are cooled by air
extracted from the tenth-stage compressor and from the compressor high
pressure seal leakage air. Wheelspace temperatures are monitored by
thermocouples.
The turbine unit casings are split for convenience of disassembly.
Compressor discharge air is contained by a separate fabricated outer shell.
The MS-5002, two shaft turbine at this site is designed to operate on gas
fuel.
1.1.4 Principals of Gas Turbine Operation
The compressor/high pressure turbine rotor is initially brought to 20%
speed by a starting device. Atmospheric air, drawn into the compressor,
flows to the combustion chambers where fuel is delivered under pressure.
A high voltage spark ignites the fuel-air mixture. (Once ignited, combus-
tion will remain continuous in chambers). The hot gases increase the
speed of the compressor/high pressure turbine rotor. This, in turn, in-
creases the compressor discharge pressure. As the pressure begins to in-
crease, the low pressure turbine rotor will begin to rotate and both turbine
rotors will accelerate to operating speed. The products of combustion,
(high pressure and high temperature gases) expand first through the high
pressure turbine and then through the low pressure turbine and are ex-
hausted to atmosphere.
As the expanding gases pass through the high pressure turbine and im-
pinge on the turbine buckets, they cause the turbine to spin; thus rotating
the compressor and applying a torque output to the driven accessories.
The gases also spin the low pressure turbine before exhausting; thus rotat-
ing the load. The rotor spins in a counterclockwise direction when
viewed from the inlet end.
06-06-E 160.5876 P. 3-9

1.2 EQUIPMENT DATA SUMMARY
GENERAL DESIGN DATA
Gas - turbine model series ..........................MS-5002C
Gas turbine application...............................Mechanical drive
Cycle...........................................................Simple
Shaft rotation ..............................................Counterclockwise
Type of operation........................................Continuous
Shaft speed..................................................4670 rpm
Control........................................................Mark VI SPEEDTRONIC
solid-state electronic
control system
Protection (basic types) ..............................Overspeed, overtemperature,
vibration and flame detection
Cooldown mechanism ................................Reduction gear with
ratchet
Sound attenuation .......................................Inlet and exhaust silencers
to meet site requirements
GAS TURBINE NAMEPLATE RATING (at O.M.A.S.L.)
Base output .................................................38000 hp - ISO condition
Inlet temperature.........................................59F
Exhaust pressure.........................................14,7 PSI
COMPRESSOR SECTION
Number of compressor stages.....................16
Compressor type.........................................Axial flow, heavy duty
Casing split .................................................Horizontal flange
Inlet guide vanes type.................................Variable
06-06-E 160.5876 P. 4-9

TURBINE SECTION
Number of turbine stages............................2 (two - shaft)
Casing split .................................................Horizontal
First-stage nozzles ......................................Fixed area
Second-stage nozzles..................................Variable
COMBUSTION SECTION
Type............................................................12 multiple combustors,
reverse flow type
Chamber arrangement.................................Concentrically located
around the compressor
Fuel nozzle..................................................Gas fuel type
1 per chamber
Spark plugs .................................................2, electrode type,
spring-injected, self-
retracting
Flame detector ............................................4, ultra-violet type
BEARING ASSEMBLIES
Quantity ......................................................4
Lubrication..................................................Pressure lubricated
No. 1 bearing assembly
(located in inlet casing assembly)...............Active and inactive
thrust and journal, all
contained in one assembly
Journal ........................................................Elliptical
Active thrust ...............................................Tilting pad, self-equalizing
Inactive thrust .............................................Tapered land
(located in the compressor discharge
casing).........................................................Journal, elliptical
(located in the exhaust frame) ....................Journal, tilting pad
06-06-E 160.5876 P. 5-9

BEARING ASSEMBLIES (continued)
(located in the exhaust frame) ....................Active and inactive thrust
and journal, all contained
in one assembly
Journal ........................................................Tilting pad
Active thrust ...............................................Tilting pad, self-equalizing
Inactive thrust .............................................Tilting pad, non-equalizing
STARTING SYSTEM
Starting device............................................Electric Motor
Reduction gear type....................................Freestanding with hydraulic
device ratchet
FUEL SYSTEM
Type............................................................Natural gas
Fuel control signal ......................................SPEEDTRONIC *
turbine control panel
Gas stop, ratio and control valve ................Electrohydraulic servo
control
LUBRICATION SYSTEM
Lubricant.....................................................Petroleum base
Total capacity .............................................23530LTS lts
Bearing header pressure..............................25 PSI (1,72 Bar)
06-06-E 160.5876 P. 6-9

LUBRICATION SYSTEM (continued)
Main lube pump..........................................Shaft-driven, integral
with accessory gear
Auxiliary lube pump...................................Motor-driven, vertical
submerged, centrifugal
sump type
Emergency lube pump................................Motor-driven, vertical,
submerged, centrifugal
sump type
Filter (Lube fluid)
Type............................................................Full flow/with transfer
valve
Quantity ......................................................Dual
Cartridge type .............................................12 micron filtration,
inorganic fiber
HYDRAULIC SUPPLY SYSTEM
Main hydraulic supply pump......................Accessory gear-driven,
variable displacement
axial piston
Auxiliary hydraulic supply pump...............Motor driven, gear-rotor type
Hydraulic supply filter(s)
Type............................................................Full flow
Quantity ......................................................Dual with transfer valve
Cartridge type .............................................5 micron filtration,
inorganic fiber
06-06-E 160.5876 P. 7-9

1.3 PERFORMANCE CURVE (SOM6609239)
See volume VIII reference drawing.
06-06-E 160.5876 P. 8-9

1.4 TURBINE TWO SHAFT DIAGRAM (SYMPLE CYCLE)
FIGURE 1-6
BLOCK DIAGRAM OF A SIMPLE-CYCLE TWO SHAFT GAS TURBINE
06-06-E 160.5876 P. 9-9

INDEX
2. GAS TURBINE DESCRIPTION....................................................................................2
2.1 GENERAL .................................................................................................................2
2.1.1 Detail orientation.................................................................................................2
2.2 TURBINE BASE........................................................................................................2
2.3 TURBINE SUPPORTS .............................................................................................3
2.3.1 Gib key and guide block......................................................................................3
2.4 ACCESSORY BASE AND SUPPORTS..................................................................4
06-06-E 160.5876 P. 1-4

2. GAS TURBINE DESCRIPTION
2.1 GENERAL
Component identification
This section of the manual describes the various assemblies, systems and compo-
nents that comprise the gas turbine. Refer to the instruction in this volume, the In-
spection and Maintenance Volume, and the Parts Lists and Drawings Volume VIII
for gas turbine component detailed information.
2.1.1 Detail orientation
Throughout this manual, reference is made to the forward and aft ends,
and to the right and left sides of the gas turbine and its components. By
definition, the air inlet of the gas turbine is the forward end, while the ex-
haust stack is the aft end. The forward and the aft ends of each compo-
nent are determined in like manner with respect to its orientation within
the complete unit. The right and left sides of the turbine or of a particular
component are determined by standing forward and looking aft.
2.2 TURBINE BASE
The base that supports the gas turbine is a structural-steel frame, fabricated of I-
beams and plates. The base frame, consisting of two longitudinal wide flange steel
beams with three cross members, forms the bed upon which the vertical supports
for the turbine are mounted.
Lifting trunnions and supports are provided, two on each side of the base, in line
with the first two structural cross members, of the base frame. Machine pads,
three on each side of the bottom of the base, facilitate its mounting on the site
foundation.
Machine pads on the top of the frame are provided for mounting the turbine sup-
ports.
06-06-E 160.5876 P. 2-4

The left and right longitudinal I-beams and the forward and aft cross members of
the turbine base are fabricated along the webs so that they form lube oil drain
channels for the turbine bearing, load coupling and load equipment. The lube oil
feed piping is contained within the longitudinal channels.
2.3 TURBINE SUPPORTS
The gas turbine is supported on the base by two flexible support plates, one under
the inlet casing and the other under the exhaust frame casing. These supports pre-
vent lateral or rotational movement of the gas turbine, but allow axial movement
which results from thermal expansion of the turbine during operation.
The inlet support plate bolted to the forward cross member of the turbine base.
The exhaust frame support plate is bolted to the aft cross member.
In order to prevent misalignment of couplings, and to prevent any strain on piping
between the bases due to thermal expansion, two centerline supports have been
provided on the bottom of the forward and middle cross members of the turbine
base. The forward support is a steel plate with a keyway which accomodates a
squard post in the foundation; this prevent lateral movement of the base centerline
due to thermal expansion. The support at the middle cross member of the turbine
base is a steel plate with a four inch diameter hole. This plate accomodates a steel
pin which prevents movement of the base in all directions.
2.3.1 Gib key and guide block
The middle cross member has a gib block welded to it and accepts the gib
key which is an integral part of the lower half exhaust frame. This key is
held securely in place with shims, forward and aft, that bear against the
gib, yet permit vertical expansion of the exhaust frame. The arrangement
locates a longitudinal fixed point of the turbine from which the unit can
thermally expand forward and aft.
06-06-E 160.5876 P. 3-4

2.4 ACCESSORY BASE AND SUPPORTS
The accessory base is a structural assembly, fabricated with steel I-beams and
plates providing a mounting platform for the accessory drive gear, starting device
and other accessories. The interior of the accessory base forms a self-contained
lube oil tank. Bottom plates of the tank are positioned at a slight angle that slopes
toward two drain pipes and plugs at one side of the base. Lube oil heat exchangers
and filters are contained within the lube oil storage tank.
Four lifting trunnions and supports are provided near each corner of the base.
Machine pads, or sole plates, located at the bottom of the base, facilitate its mount-
ing to the site foundation: Two centerline supports, similar to those on the turbine
base, are also provided to prevent misalignment due to thermal expansion.
06-06-E 160.5876 P. 4-4

INDEX
3. COMPRESSOR SECTION.............................................................................................2
3.1 GENERAL .................................................................................................................2
3.2 COMPRESSOR ROTOR .........................................................................................2
3.3 COMPRESSOR STATOR........................................................................................3
3.4 INLET CASING ........................................................................................................3
3.5 COMPRESSOR CASING ........................................................................................4
3.6 COMPRESSOR DISCHARGE CASING ...............................................................4
06-06-E 160.5876 P. 1-7

3. COMPRESSOR SECTION
3.1 GENERAL
The axial-flow compressor section consists of the compressor rotor and casing
which includes the sixteen stages of compression, variable inlet guide vanes, and
two exit guide vanes.
In the compressor, air is confined to the space between the rotor and stator blading
where it is compressed in stages by a series of alternate rotating (rotor) and sta-
tionary (stator) air-foil shaped blades. Rotor blades supply the force needed to
compress the air in each stage and the stator blades guide the air so that it enters
the following rotor stage at the proper angle. The compressed air exits through the
compressor discharge casing to the combustion wrapper and the combustion
chambers. Air is also extracted from the compressor for turbine cooling, and for
bearing lube oil sealing.
3.2 COMPRESSOR ROTOR
The compressor rotor is an assembly of sixteen wheels, a stub shaft, tie bolts, and
the compressor rotor blades.
Each wheel and the wheel portion of the forward stub shaft has borached slots
around its periphery. Rotor blades are inserted into these slots and held in axial
position by spacer pieces which are in turn staked at each end of the slot. These
blades are airfoil shaped and were designed to compress air efficiently at high
blade tip velocities. The wheels and stub shafts are assembled to each other with
mating rabbets for concentricity control and are held together with tie bolts. Se-
lective positioning of the wheel is made to reduce balance correction. After as-
sembly, the rotor is dynamically balanced to a fine limit.
The forward stub shaft is to provide the forward and aft thrust faces and the jour-
nal for the No. 1 bearing oil seals and the compressor air seal (see Fig. 3.1).
06-06-E 160.5876 P. 2-7

3.3 COMPRESSOR STATOR
The stator (casing) area of the compressor section is composed of three major sec-
tions:
a. Inlet casing
b. Compressor casing
c. Compressor discharge casing
These sections, in conjunction with the turbine shell, form the primary external
structure of the gas turbine. They support the rotor at the bearing points and con-
stitute the outer wall of the gas-path annulus. The casing bore is maintained to
close tolerances with respect to the rotor blade tips for maximum efficiency. (See
Fig. 3-2).
3.4 INLET CASING
The inlet casing is located at the forward end of the gas turbine. Its prime function
is to uniformly direct air into the compressor. The casing also supports the No. 1
bearing assembly whose lower-half housing is a separate casing, flanged and
bolted to the casing lower half. The inner bellmouth is positioned to the outer
bellmouth by seven airfoil-shaped radial struts and seven axial tiebars. Both the
struts and tiebars are cased in the bellmouth walls: Variable inlet guide vanes are
installed in the aft end of the inlet casing. The variable inlet guide vanes permit
fast, smooth acceleration of the turbine without compressor surge (pulsation).
Hydraulic oil is utilized to activate the inlet guide vanes through a large ring gear
and multiple small pinion gears. At startup, the vanes are set at the 44 degree po-
sition which is the closed position.
The inlet casing also transfers the structural loads from the adjoining casings to the
forward support which is bolted and doweled to the lower half of the casing on the
forward side.
06-06-E 160.5876 P. 3-7

3.5 COMPRESSOR CASING
The compressor casing contains the first ten compressor-stator stages. The com-
pressor casing is equipped with two large integrally cast trunnions which are used
to lift the gas turbine when it is separated from its base.
The first four stages of the stator blades in the compressor casing are assembled in
slotted semi-circular rings.
The stator blade and ring assemblies are then installed in dovetail grooves ma-
chined in the wall of the compressor casing. Locking keys, which are installed in
a groove machined on the left and right side of the horizontal joint flange of the
casing upper half, keeps these assemblies from rotating in the stator grooves and
from falling down when the upper half of the casing is lifted.
The fifth to tenth stator blade stages are installed on dovetails grooves machined
in the wall of the compressor casing. Long locking keys, which are installed in
grooves machined in the left and right side of the horizontal flange of the casing
upper half, keep the stator blades from rotating in the stator grooves and from fal-
ling down when the upper half of the compressor casing is lifted.
3.6 COMPRESSOR DISCHARGE CASING
The compressor discharge casing is the rear portion of the compressor section. It
is the longest single casing, situated at the midpoint between the forward and aft
turbine supports. The functions of the compressor discharge casing are to contain
the balance of compressor surges, to form both the inner and outer walls of the
compressor diffuser, and to join the compressor and turbine stators. It also pro-
vides support for the first-stage the turbine nozzle.
The compressor discharge casing consists of two cylinders, one being a continua-
tion of the compressor casing and the other being an inner cylinder that surrounds
the compressor rotor. The two cylinders are concentrically positioned by eight ra-
dial struts which flair out to meet the large diameter of the turbine shell, and are
the primary load bearing members in this portion of the gas turbine stator.
The supporting structure for the No. 2 bearing is contained within the inner cylin-
der. A diffuser is formed by the tapered annulus between the outer cylinder and
inner cylinder of the discharge casing. The diffuser converts some of the compres-
sor exit velocity into added pressure.
06-06-E 160.5876 P. 4-7

The compressor discharge casing contains the remaining six (stator blade stages
eleventh to sixteenth and the two exit guide vanes blade rows, which are com-
posed by simple blades installed in dovetails grooves machined in the wall of the
compressor discharge casing.) Locking keys installed in grooves machined in the
horizontal joint flanges of the casing upper half impident the rotation of the blades
and serve to prevent the stator blades from dropping out of the grooves when the
discharge casing upper half is lifted.
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FIG. 3.1 - VIEW OF COMPRESSOR H.P. TURBINE ROTOR ASSEMBLY
06-06-E 160.5876 P. 6-7

FIG. 3.2 - MODEL 5002 COMPRESSOR CASING AND H.P. TURBINE ROTOR
ASSEMBLY
06-06-E 160.5876 P. 7-7

INDEX
4. COMBUSTION SECTION.............................................................................................2
4.1 GENERAL .................................................................................................................2
4.2 COMBUSTION WRAPPER (SHORT)...................................................................2
4.3 COMBUSTION CHAMBERS .................................................................................3
4.3.1 Spark plugs ..........................................................................................................3
4.3.2 Ultraviolet flame detectors ..................................................................................4
4.3.3 Fuel nozzles.........................................................................................................5
4.3.4 Crossfire tubes.....................................................................................................5
06-06-E 160.5876 P. 1-8

GE Oil & Gas MS 5002 C Gas Turbine Manual

GE Oil & Gas MS 5002 C Gas Turbine Manual

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GE Oil & Gas MS 5002 C Gas Turbine Manual