Taurus Group 60 User Manual

TAURUS 60

Turbomachinery Package Specification

Oil & Ga s Applic at i o n s

Compressor Set and

Mechanical Drive

TURBOMACHINERY PACKAGE

SPECIFICATION

Taurus

60 Compressor Set and

Mechanical Drive

Solar Turbines Incorporated P.O. Box 85376 San Diego, CA 92186-5376

Caterpillar is a trademark of Caterpillar Inc. Solar, Taurus, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated. All other trademarks, service marks, or registered trademarks appearing in this specification are the intellectual property of their respective companies. Specifications are subject to change without notice.

Direct customers of Solar Turbines Incorporated that receive this Turbomachinery Package Specification directly from Solar Turbines Incorporated may make limited copies of parts of this specification for use in the creation of their own specification documents. However, such customers shall not distribute any part of this Turbomachinery Package Specification outside their own organizations for any other purpose. Any other use without the permission of Solar Turbines Incorporated is strictly prohibited.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Table of Contents

1 INTRODUCTION.....................................................................................................................5

1.1 General Description........................................................................................................5

1.2 Overview.........................................................................................................................5

1.3 Terminology....................................................................................................................5

2 TAURUS 60 GAS TURBINE MECHANICAL DRIVE .............................................................6

2.1 General Description........................................................................................................6

2.2 Package Description ......................................................................................................6

3 TAURUS 60 GAS TURBINE.................................................................................................10

3.1 General Description......................................................................................................10

4 SOLAR COMPRESSOR SET PACKAGES .........................................................................13

4.1 Compressor Set Packages...........................................................................................13

4.2 Solar Gas Compressors...............................................................................................13

5 MECHANICAL DRIVE PACKAGES.....................................................................................18

5.1 Mechanical Drives........................................................................................................18

6 GEARBOX ............................................................................................................................20

6.1 General Description......................................................................................................20

7 START SYSTEM...................................................................................................................22

7.1 General Description......................................................................................................22

7.2 Direct-Drive AC Start System.......................................................................................22

7.3 Pneumatic Start System (Optional)..............................................................................25

8 FUEL SYSTEM .....................................................................................................................26

8.1 General Description......................................................................................................26

9 LUBRICATION SYSTEM......................................................................................................29

9.1 General Description......................................................................................................29

10 TURBOTRONIC 4 CONTROL SYSTEM..............................................................................34

10.1 General Description......................................................................................................34

10.2 System Architecture .....................................................................................................34

10.3 Component Descriptions ..............................................................................................36

10.4 System Monitoring and Control Functions ...................................................................37

10.5 TT4000 Display and Monitoring System ......................................................................39

11 COMPRESSOR CONTROL AND MONITORING................................................................44

11.1 General Description......................................................................................................44

12 ENCLOSURE........................................................................................................................47

12.1 General Description......................................................................................................47

12.2 Standard Features........................................................................................................48

12.3 Optional Features.........................................................................................................50

13 AIR INLET SYSTEM.............................................................................................................54

13.1 General Description......................................................................................................54

14 EXHAUST SYSTEM..............................................................................................................60

14.1 General Description......................................................................................................60

14.2 Turbine Exhaust Heat Recovery System .....................................................................60

15 ACCESSORY EQUIPMENT .................................................................................................62

15.1 Battery Charger System ...............................................................................................62

15.2 Turbine Cleaning System.............................................................................................62

16 MARINIZATION ....................................................................................................................65

16.1 General Description......................................................................................................65

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

17 QUALITY ASSURANCE AND TESTING .............................................................................67

17.1 Quality Assurance ........................................................................................................67

17.2 Testing..........................................................................................................................67

18 PRESERVATION, INSTALLATION, AND DOCUMENTATION...........................................70

18.1 General Description......................................................................................................70

18.2 Preservation .................................................................................................................70

18.3 Site Requirements........................................................................................................70

18.4 Mechanical Installation.................................................................................................71

18.5 Documentation .............................................................................................................71

19 CERTIFICATION...................................................................................................................73

19.1 General Description......................................................................................................73

19.2 National Electrical Code ...............................................................................................73

19.3 Canadian Electrical Code.............................................................................................73

19.4 Conformité Européenne Mark ......................................................................................74

19.5 International Electrotechnical Commission Safety Assessment ..................................75

19.6 Offshore Marine Applications .......................................................................................75

19.7 Summary ......................................................................................................................76

20 SUPPORT SERVICES..........................................................................................................77

20.1 Construction Services ..................................................................................................77

20.2 Customer Services.......................................................................................................77

20.3 Contract Power and Leasing Services .........................................................................78

20.4 Solar’s Worldwide Locations ........................................................................................78

CONVERSION CHART..................................................................................................................79

LIST OF ABBREVIATIONS...........................................................................................................80

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Table of Figures

Figure 1. Typical Taurus 60 Gas Turbine Mechanical Drive......................................................6

Figure 2. Typical Taurus 60 Mechanical Drive Service Connections ........................................7

Figure 3. Typical Taurus 60 Two-Shaft Gas Turbine...............................................................10

Figure 4. Typical Combustion Process ....................................................................................11

Figure 5. Compressor Set with Taurus 60 Driving Tandem Solar Compressors.....................13

Figure 6. Cutaway Diagram of a Solar Gas Compressor ........................................................14

Figure 7. Cross Section of a Solar Gas Compressor...............................................................14

Figure 8. Typical Gearbox........................................................................................................20

Figure 9. Typical Direct-Drive AC Starter Motor and Variable Frequency Drive .....................23

Figure 10. Typical Direct-Drive AC Start System.......................................................................23

Figure 11. Typical Pneumatic Start System...............................................................................25

Figure 12. Typical Fuel System Schematic................................................................................26

Figure 13. Typical Lube Oil System ...........................................................................................30

Figure 14. Typical Onskid Control System.................................................................................35

Figure 15. Typical Offskid Control System.................................................................................35

Figure 16. Turbotronic System Architecture ..............................................................................36

Figure 17. Typical TT4000 Operation Summary Screen ...........................................................40

Figure 18. Typical TT4000 Strip Chart Screen ..........................................................................40

Figure 19. Typical TT4000S Engine Summary Screen..............................................................41

Figure 20. Typical Taurus 60 Enclosure ....................................................................................47

Figure 21. Typical Fire and Gas System....................................................................................49

Figure 22. Typical CO2 Suppression Fire Cylinder Cabinets .....................................................51

Figure 23. Typical Water Mist Suppression Fire Cylinder Cabinet ............................................52

Figure 24. Typical Enclosed Taurus 60 Package with Exhaust and Inlet Systems...................54

Figure 25. Typical Taurus 60 High Velocity Air Inlet System.....................................................56

Figure 26. Typical Taurus 60 Medium Velocity Air Inlet System ...............................................57

Figure 27. Typical Battery Charger ............................................................................................62

Figure 28. Turbine Cleaning System .........................................................................................63

Figure 29. Turbine Cleaning Cart...............................................................................................63

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

1 Introduction

1.1 General Description

Solar Turbines Incorporated is a worldwide leader in the design, manufacture, and installation of industrial gas turbines. Solar's 40 years of experience integrating high technology with fluid compression, liquid pumping, power generation, and cogeneration applications has resulted in more than 12,500 gas turbine installations in 93 countries around the world. Solar gas turbine packages have logged more than 1.3 billion operating hours around the world in a wide range of applications. Solar gas turbine packages are complete packaged systems that require a minimum of site preparation prior to installation.

Taurus 60 compressor sets and mechanical drives represent years of intensive engineering and manufacturing design. Solar gas turbines are manufactured to rigid industrial standards and are thoroughly tested in modern facilities. Solar's operations are certified by Det Norske Veritas (DNV) to conform to International Standardization Organization (ISO) 9001:2000 Standard for Quality Management Systems.

1.2 Overview

This document describes product features and provides turbomachinery package specifications for Taurus 60 compressor sets and mechanical drives. Presented within this booklet are basic package configurations, ancillary descriptions, installation requirements, and a list of customer support services available at the time of publication. Please note that changes in equipment, service descriptions, and specifications may occur without prior notice.

1.3 Terminology

In describing different package configurations, Solar uses the term “Mechanical Drive” to cover the gas turbine packaged on a skid with all the required accessory equipment required for operation. The term “Compressor Set” is used when the mechanical drive package is combined with a Solar gas compressor packaged on its own skid. Compressor Sets are fully integrated packages, although the driver and driven packages may be shipped separately for logistical reasons. When the mechanical drive is provided for use with a third party’s driven equipment, typically either a gas compressor or a pump, Solar will work with the driven equipment supplier to ensure that the two packages are properly interfaced. Control and monitoring of the driven equipment is usually in Solar’s scope of supply and will be integrated into the Turbotronic control system.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

2 Taurus 60 Gas Turbine Mechanical Drive

2.1 General Description

The Taurus 60 gas turbine mechanical drive package is completely integrated and fully operational, equipped with the accessories and auxiliary systems required for operation. In addition to the standard package features, a wide array of optional equipment is available to meet customers’ installation and operation requirements. The driver package can be combined with one or more Solar centrifugal gas compressors to form a complete compressor set (see section 4) or it can be used to drive other manufacturers’ gas compressors or pumps (see section 5). Designed specifically for industrial service, Taurus 60 packages are compact, lightweight units requiring minimal floor space for installation. Proven packaging designs greatly reduce installation costs, time, materials, and labor. Figure 1 shows a side view of a typical Taurus 60 Mechanical Drive package.

Figure 1. Typical Taurus 60 Gas Turbine Mechanical Drive

2.2 Package Description

The Taurus 60 gas turbine package is installed on a steel base frame referred to as the skid. The skid is a structural steel assembly with beam sections and cross members welded together to form a rigid foundation. Drip pans are included to collect any potential liquid leakage. Package connection points for fuel, lube oil, air, and water are located on the outer edge of the skid. Electrical connections are made in on-skid junction boxes. Machined mounting surfaces on the base frame facilitate component alignment. Major Components and Systems

Major components and systems of the Taurus 60 mechanical drive package typically include:

• Gas turbine

• Start system

• Fuel system

• Lubricating oil system

• Turbotronic 4 Control System

• Onskid electrical wiring

• Skid with drip pans

• Piping and manifolds

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

• Ancillary air inlet system

• Ancillary exhaust system

• Package enclosure (if specified) with:

− Ventilation system

− Fire detection and suppression system

− Combustible gas detection

2.2.1 Package Electrical System

The onskid package electrical system can be furnished to meet the following certification requirements:

• National Electrical Code (NEC)

• Canadian Electrical Code (CEC)

• Conformité Européenne (CE) Mark (includes compliance to the ATEX directive)

• European Committee for Electrotechnical Standardization (CENELEC)

When supplied, the off-skid control console, variable frequency drives, and battery charger are not approved for hazardous duty areas and must be installed in a nonhazardous area.

Three-Phase Motor Voltage

All three-phase motors and three-phase electrical components have the same voltage rating. Motor starters and contactors are not provided.

2.2.2 Service Connections

The Taurus 60 Mechanical Drive is supplied with self-contained systems for starting, fuel, lube oil and control. All service connections (Figure 2) are conveniently located on the outer edge of the skid.

Figure 2. Typical Taurus 60 Mechanical Drive Service Connections

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Table 1. Package Specifications

Dimensions

Approximate Package Measurements

Height, Unenclosed 2.72 m (8 ft 11 in.) Height, Enclosed 3.20 m (10 ft 6 in.) Width (to skid edges) 2.46 m (8 ft 1 in.) Width (including lifting bollards) 2.59 m (8 ft 6 in.) Length, Engine Skid 6.02 m (19 ft 9 in.)

Approximate Package Weights

AC Start Motor Assembly 370 kg (820 lb) Pneumatic Start Assembly 260 kg (570 lb) Gas Turbine Assembly (SoLoNOx) 3290 kg (7250 lb) Total Driver (unenclosed package, without oil) 15 422 kg (34,000 lb) Total Driver (enclosed package, with oil) 20 607 kg (45,430 lb)

Piping and Tubing Thickness

Piping > 76.2 mm (3 in.) Nominal Pipe Size (NPS) Schedule 40 (Unless Otherwise Specified) Piping < 50.8 mm (2 in.) NPS Schedule 80 (Unless Otherwise Specified) Tubing 3.175 mm (0.125 in.) Nominal Tubing Size

(NTS) Tubing 6.35 mm (0.25 in.) NTS 1.245 mm (0.049 in.) Minimum Wall Thickness Tubing 12.7 mm (0.500 in.) NTS 1.651 mm (0.065 in.) Minimum Wall Thickness Tubing 19.05 mm (0.75 in.) NTS 1.651 mm (0.065 in.) Minimum Wall Thickness Tubing 25.40 mm (1.00 in.) NTS 2.108 mm (0.083 in.) Minimum Wall Thickness Tubing 31.75 mm (1.25 in.) NTS 2.768 mm (0.109 in.) Minimum Wall Thickness

Construction Materials

Piping, Manifolds, and Tubing < 10.2 cm (4 in.) Note (a)

Piping, Manifolds, and Tubing > 10.2 cm (4 in.) Note (a)

Piping Interface Connections 316L Stainless Steel (Unless Otherwise Specified) Flange Assembly Hardware 316L Stainless Steel Pipe Support Brackets

Pipe Flexible Couplings

Tubing Dual Ferrule Compression Fittings 316L Stainless Steel Sliding Lube Oil Drain Couplings and Plates

Lube Oil Vent Flame Arrestor

Electrical System Certifications

NEC Class 1, Group D, Division 1 or 2 CENELEC Zone 1 or 2, Group II CE, ATEX Zone 2, Group II

Three-Phase Package Motors

Optional Motor Voltage Ratings

Single-Phase Battery Charger

Optional Battery Charger Voltage Ratings

0.889 mm (0.035 in.) Minimum Wall Thickness

316L Stainless Steel (Unless Otherwise Specified)

Carbon Steel (Unless Otherwise Specified)

Carbon Steel (Standard) 316L Stainless Steel (Optional)

380, 400, or 415 VAC, 50 Hz 460 VAC 60 Hz

220, 230, 240, 380, 400, 415, 440, 460, or 480 VAC, 50 Hz or 60 Hz

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Single-Phase Lighting and Space Heater Voltage

Optional Package Lighting and Space Heater Voltage Ratings

Ingress Protection (IP) Ratings

Onskid Junction Boxes IP56 to IP66 Control Console IP50 Battery Charger, NEC IP22 Battery Charger, CE IP31

Solar’s Applicable Engineering Specifications

ES 9-56 Fusion Welding ES 9-58 Standard Paint Program – Turbo Machinery ES 1593

ES 1762

ES 2201 Auxiliary Air ES 2231

Solar’s Applicable Product Information Letters

PIL 127 Product Certification PIL 140 Dry Gas Face Seals for Solar Compressors

Notes:

(a) All package piping is fabricated from 316L stainless steel with the exception of lube oil vent

lines and any piping welded directly to a carbon steel lube oil tank or tank cover.

Guidelines for NEC Compliance of Solar’s Product Lines: Class I, Group D, Division 1 and Division 2

Standards and Practices for Electrical Systems for Gas Turbine Packages Installed In Hazardous Areas (CENELEC/IEC Standards – European ATEX Directive 94/9/EC)

Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1, Division 2 Hazardous Areas

120, 220, 230, or 240 VAC, 50 Hz or 60 Hz

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

3 Taurus 60 Gas Turbine

3.1 General Description

The two-shaft Taurus 60 gas turbine (Figure 3) is a completely integrated and selfcontained prime mover. The gas turbine combines high performance operation with rugged industrial construction. This design philosophy allows for high efficiency, low maintenance, and a long service life. The Taurus 60 gas turbine is designed for a high degree of compliance with American Petroleum Institute (API) requirements.

Figure 3. Typical Taurus 60 Two-Shaft Gas Turbine

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

3.1.1 Principles of Operation

During the typical combustion process (Figure 4), air is drawn into the gas turbine air inlet and is compressed by the multi-stage, axial-flow engine compressor. The compressed air is directed into the annular combustion chamber at a steady flow. Fuel is injected and mixed with the compressed air and ignited during the start cycle. Continuous combustion will be maintained as long as there is an adequate flow of pressurized air and fuel. Hotpressurized gas from the combustor expands through and drives the turbine, dropping in pressure and temperature as it exits the turbine. This combustion cycle converts the energy in the fuel into kinetic rotating power at the turbine output shaft.

For combustion, the gas turbine requires approximately one-fourth of the total air it compresses. The excess air is mixed with the combustion products to reduce the gas temperature at the turbine first stage-inlet. The cooling air also keeps metal temperatures in the combustor and turbine assembly relatively low to ensure a long service life.

Figure 4. Typical Combustion Process

3.1.2 SoLoNOx Combustion System (Optional)

In addition to the conventional combustion system, Solar’s proprietary SoLoNOx dry emissions system reduces pollution by limiting the formation of nitrous oxides (NOx), carbon monoxide (CO), and unburned hydrocarbons (UHC). This system uses lean premix combustion to lower the maximum flame temperature and reduce pollution formation. Solar’s engineering staff works with customer’s to meet local permitting emission requirements.

Table 2. Taurus 60 CSMD Gas Turbine Specifications

Compressor

Type Axial Flow Number of Stages 12

Compression Ratio

Flow (Nominal)

Combustion Chamber

Type Annular Ignition Torch Number of Fuel Injectors 12

Gas Producer Turbine

Type Reaction Number of Stages 2 Maximum Speed 15,000 rpm

12.2:1 (Compressor Set)

11.5:1 (Mechanical Drive)

21.3 kg/sec (47.0 lb/sec) (Compressor Set)

21.1 kg/sec (46.5 lb/sec) (Mechanical Drive)

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Power Turbine

Type Reaction Number of Stages 2 Maximum Speed 14,300 rpm

Bearings

Radial 3 Tilt Pad with Proximity Probes Thrust 1 Tilt Pad with Resistance Temperature Device Probes

Construction Materials

Compressor Case

Forward Section Nodular Iron

Aft Section WC6 Alloy Steel Combustor Case 410 Stainless Steel Exhaust Diffuser Nodular Iron Accessory Gear Housing Ductile Iron

Protective Coatings

Compressor Rotor and Stator Blades Inorganic Aluminum Nozzles, First and Second Stage Precious Metal Diffusion Aluminide Blades, First and Second Stage Precious Metal Diffusion Aluminide

Performance

Output Power

5740 kW (7700 hp), See Note (a)

Heat Rate 11 265 kJ/ kW-hr (7960 Btu/ kW-hr)

Exhaust Flow 77 880 kg/hr (171,690 lb/hr)

Exhaust Temperature 510°C (950°F)

Vibration Monitoring

Turbine Bearing #1 Displacement Probes, X and Y axis Turbine Bearing #2 Displacement Probes, X and Y axis Turbine Bearing #3 Displacement Probes, X and Y axis Turbine Bearing #4 Displacement Probes, X and Y axis Turbine Bearing #5 Displacement Probes, X and Y axis Turbine Rotor Shaft Displacement Probe, Axial Position Turbine Rotor Shaft Keyphasor

Notes:

(a) Performance on gas fuel is calculated under the following conditions:

Nominal Rating - ISO at 15°C (59°F), Sea Level No Inlet/Exhaust Losses Relative Humidity at 60% LHV = 31.5 to 43.3 MJ/nm

(800 to 1,100 Btu/scf)

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

4 Solar Compressor Set Packages

4.1 Compressor Set Packages

Solar offers complete and fully integrated compressor set packages with the Taurus 60 gas turbines driving one or more Solar centrifugal gas compressors (Figure 5). The packages are fully operational and include all the necessary accessories, auxiliary and control systems. The compressor sets combine the gas turbine driver with matching integrated centrifugal compressor modules, available in single-body, two-body, or threebody tandem configurations for direct-drive or gear-driven applications. Compressor sets with a single Solar compressor can produce pressure ratios of over 3:1 while multiple, tandem-mounted compressors can produce pressure ratios approaching 30:1.

Solar compressor sets are complete with all unique system requirements built into the basic package. This inherent single-source responsibility eliminates any risk of drive train incompatibility or performance questions that may arise when the driver and the driven compressor are built by different manufacturers.

Figure 5. Compressor Set with Taurus 60 Driving Tandem Solar Compressors

4.2 Solar Gas Compressors

Solar offers a broad range of centrifugal gas compressors for both gas production and gas pipeline applications. Table 3 lists the Solar compressor products that are suitable for operation with the Taurus 60 gas turbine. Solar’s approach to compressor design is to maximize simplicity and flexibility. Solar minimum of three years of continuous full-load duty between inspections, and major components are designed for 20 years of continuous operation. Many features commonly used in Solar compressor designs conform to American Petroleum Institute (API) 617.

Standard features include:

• Vertically split barrel-type construction

• Tilt-pad journal bearings

• Self-aligning tilt-pad thrust bearings

• Rigid modular rotor construction

• Rotor trim balancing

• Overcompensating balance piston

• Radial vibration measurement

• Thrust bearing temperature sensors

gas compressors are designed to achieve a

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

For more details about Solar centrifugal compressors, please consult Solar’s engineering for project specific gas compressors. Figures 6 and 7 show the internal construction of typical Solar compressors.

Figure 6. Cutaway Diagram of a Solar Gas Compressor

Figure 7. Cross Section of a Solar Gas Compressor

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Table 3. Typical Solar Gas Compressors

Compressor

Family

For Gas Production Applications

C16 1-10 20 700 3000 50 1800 215 72,000 C33 1-12 15 510 2250 270 9500 325 108,000 C40 1-6 17 240 2500 255 9000 255 85,000 C50 1-5 10 350 1500 565 20,000 285 95,000

For Gas Pipeline Applications

C40 1-2 11 040 1600 270 9500 95 32,000

Number

of Stages

Maximum Pressure

Rating

kPa psig m3/min ft3/min kJ/kg ft-lbf/lb

Maximum Flow Maximum Total Head

4.2.1 Impellers

Compressor impellers are designed to conservative stress levels. All impellers are suitable for sour gas applications. Each impeller, after machining, is proof tested to 115% of its maximum mechanical speed.

4.2.2 Rotor Assembly

The rotor assembly consists of stub shafts, impellers, and, if required, rotor spacers (to maintain a constant bearing span) and a centerbolt. These components are individually balanced and are rabbet-fit to each other for concentric alignment. Torque is transmitted through dowel pins. The entire assembly is clamped together with the centerbolt. The rotor assembly is easy to disassemble. The benefits from this type of construction are two-fold. Impellers that can be used in a “restaged” rotor are easily salvaged and downtime is minimized. Reusing old impellers, instead of purchasing new ones to match new operating conditions, enhances the economic feasibility of restaging to maintain optimum compressor performance and the lowest possible operating costs.

4.2.3 Casings

The pressure-containing outer casing of a compressor is an assembly of three components: the suction and discharge end caps, which contain the bearing and seal assemblies, and the centerbody, which holds the rotor and stator assemblies. This is considered a vertically split “barrel” design. The end caps contain all the service ports for oil and gas supply and discharge.

4.2.4 Compressor Module

The compressor module includes the centrifugal compressor(s) mounted on a structural steel matching base that, when bolted to the driver skid, forms a continuous base plate on which all the required subsystems are installed.

4.2.5 Lube Oil System

The gas turbine, gearbox (if required), and compressor modules have a common lube oil system.

4.2.6 Compressor Dry Seal System

The dry seal system consists of the seal gas and separation gas systems. The seal system maintains a barrier between the process gas and the compressor bearings. The separation gas system maintains a barrier between the compressor bearing lube oil and the dry gas seals.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Seal Gas System

The seal gas system consists of a primary and secondary gas face seal to prevent the escape of process gas for each shaft end. The primary dry seal takes the full pressure drop. It is used to provide the main sealing function. The secondary or backup seal acts as an emergency barrier between the process gas and the atmosphere and operates at a zero pressure differential.

The system can use clean and dry process gas or an independent clean and dry gas source as seal gas. A customer-furnished separation gas source of air or nitrogen is required to isolate lube oil from the seal gas. The separation gas must be available at all times during lube oil pump operation. Typical seal gas supply flow is 1.34 to 3.35 nm

/min (50 to 125 scfm) at 689 kPag (100 psig) above maximum suction pressure, depending on the compressor model and suction pressure. The seal gas flow rates are metered by maintaining a constant pressure drop across a flow-limiting orifice in each seal gas supply line to each compressor seal capsule. Differential pressure switches provide low flow alarm and shutdown functions.

The seal gas supply flow is higher than the primary seal leakage. The majority of the seal gas flow travels past the compressor shaft labyrinth seals and into the compressor case. This ensures the dry seal cavity is flushed with clean dry gas and that the dry seal operates in a clean environment. The seal gas may be supplied from the compressor discharge, preferably downstream of the gas cooler, provided the process gas is clean and dry.

The onskid duplex seal gas coalescing filters are designed for typical clean transmission pipeline conditions. If larger particle or liquid loads are expected, a larger off-skid filtration system with a high pressure external seal gas supply is recommended. When the seal gas is supplied from the compressor discharge but the compressor is not operating with a pressure ratio (start-up, shutdown, or pressurized hold), there is no flow of seal gas through the filters. During these times, the gas leakage across the dry seals is raw process gas from the compressor case.

This is normally not a problem on clean transmission pipeline applications; however, it may be an issue on new pipelines during initial operation, or on pipelines handling wet and/or dirty gas. Under these conditions, an external high-pressure seal gas supply is recommended. Leakage past the primary dry seals is measured by monitoring the pressure drop across an orifice run. High leakage flow alarms and shutdowns are provided by pressure switches. Primary and secondary seal vent lines must be vented by the customer to a safe location.

Separation Gas System

A circumferential buffer air or nitrogen circumferential-segmented split-ring type seal provides a barrier between the compressor bearing lube oil and the dry gas seals. It is the most outboard component of the complete seal assembly. Air flows between the seal rings and the compressor stub shaft. Separation gas flowing past the outboard seal mixes with lubricating oil and drains to the lube oil reservoir. Air flowing past the inboard seal is vented through the secondary seal gas/buffer air vent.

The separation gas source may be clean dry shop air, instrument air, or nitrogen. The system includes a hand valve for maintenance, a coalescing filter, a differential pressure regulator, and pressure switches and gauges to monitor the separation gas differential pressure. The system forms a positive separation between the lube oil and the dry seal. Flame arrestors are supplied for the primary and secondary vents. Leakage seal gas and separation gas must be piped away by the customer to selected safe areas.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

4.2.7 Hydrostatic Testing

Hydrostatic pressure testing of all compressor casings and end caps is done per API 617 for 30 minutes at 1.5 times the maximum casing design pressure, regardless of application. Test water is treated with a wetting agent to allow better penetration of possible casing defects. After the hydro and final magnetic particle test, the casing is steam cleaned and bead blasted for surface preparation. Afterwards, it is painted per Solar’s specification ES 9-58.

4.2.8 Shaft Coupling

Solar’s standard shaft interconnect is a Kop-Flex dry coupling.

4.2.9 Preliminary Alignment

The drive train is aligned preliminarily at the factory to simplify final field alignment.

Table 4. Driven Equipment and Associated Equipment Specifications

Typical Driven Skid Weight

One to Three Compressor Bodies 6800 to 34 000 kg (15,000 to 75,000 lb)

Typical Driven Skid Lengths

One to Three Compressor Bodies 4.0 to 10 m (13 to 33 ft)

Compressor Inspection Interval

Major Inspection Interval Three Years of Continuous Full-Load Duty

Compressor Construction Materials

Impeller 15-5PH, Type 100 Casing ASTM A216 GR WCC Diaphragm/Guide Vane Alloy Steel Rotor Spacer Alloy Steel Stub Shafts AISI 4140 Labyrinth Steel-Backed Babbitt

Compressor Bearings

Journal Bearing Tilting Pad Thrust Bearing Self Aligning, Tilting Pad

Compressor Vibration Monitoring

Driver End Bearing Displacement Probes, X and Y Axis Driven End Bearing Displacement Probes, X and Y Axis Thrust Bearing Displacement Probe, Axial Compressor Rotor Shaft Keyphasor

Seal Gas

Fluid Clean Process Gas or Nitrogen Particle Size Less Than 2 micron Minimum Supply Pressure

Maximum Supply Pressure 13 790 kPag (2000 psig) Flow 1.3 to 3.3 nm3/min (50 to 125 SCFM) Temperature 0 to 93°C (32 to 200°F)

Separation Gas

Air Quality

Supply Pressure 517 to 1344 kPag (75 to 195 psig) Flow 0.134 nm3/min (5 SCFM)

Solar’s Applicable Engineering Specifications

ES 9-58 Standard Paint Program - Turbomachinery

689 kPag (100 psig) above highest compressor suction pressure but below pressure rating of seal system

Refer to Solar Engineering Specification ES 2201

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

5 Mechanical Drive Packages

5.1 Mechanical Drives

The Taurus 60 gas turbine mechanical-drive package is designed for a variety of driven equipment, including centrifugal pumps and centrifugal, rotary, and reciprocating compressors. The Taurus 60 gas turbine is well suited to drive pumps and compressors, where its variable-speed capability can be used to advantage in adjusting to changing specific gravity and flow.

Solar's mechanical-drive units are widely used for crude oil or liquid product pumping and water flooding applications. As an option, Solar can provide a gear to match the speed of the driven equipment to that of the gas turbine. The gear can be located either on the driven equipment skid or on a separate skid between the driver and driven equipment skids.

5.1.1 Unitized Packaging

While the gas turbine driver package can be supplied separately for integration by others into a complete system, Solar also offers unitized packages. When a unitized package is supplied, Solar’s scope of supply may include the following options:

Driven Equipment

Supplied by original equipment manufacturers in compliance with customer requirements and Solar’s procurement specifications.

Mating Baseplate

The separate structural steel driver skid and driven equipment skid (optional) have mating flanges so they can be rigidly bolted together at the installation site. The skids may also be bolted and dowelled together at the factory and then separated for shipment.

Shaft Coupling

Several supplier-furnished shaft coupling styles are available. Coupling hubs may be mounted on both shafts at the factory. A coupling guard is included.

Preliminary Alignment

A preliminary alignment of the gas turbine driver and the driven equipment shafts can be performed at the factory to simplify final field alignment.

Unitized Lubrication and Cooling

On packages using compressors or pumps with sleeve or tilt-pad bearings, the bearings may be force fed with cooled oil from the gas turbine lubrication system. Pumps with antifriction bearings are usually furnished with self-contained ring oiling and the oil is cooled by the product being pumped.

Unitized Controls

Driven equipment protective devices may be integrated into the package control system to provide alarms and shutdowns for a variety of abnormal operating conditions, including low suction and high discharge pressure, seal leakage, high bearing or case temperature, excessive vibration, or any other measurable quantity. Additionally, driven equipment valving (suction, discharge, bypass, vent) may be integrated into the start-up and shutdown sequence controls, so those valves are automatically actuated and monitored. Additional digital and analog values can also be monitored by the control system.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Single-Source Responsibility

Solar is able to provide overall coordination to ensure that the unitized package will perform to its full potential with a minimum of installation time and cost. Performance characteristics of the driver and driven equipment are analyzed to provide an optimum match at design and off-design conditions. Installation drawings and technical manuals are prepared for customer use, detailing mechanical/electrical interface and alignment instructions. Consistency in surface preparation and painting, preservation, shipment and warranty is ensured by Solar’s Quality Assurance.

Unitizing at Installation Site

Solar’s Customer Services personnel can interface and unitize the equipment at the installation site as required.

5.1.2 Non-Unitized Packaging

When the gas turbine package is furnished without driven equipment, Solar cannot ensure proper interface between the gas turbine and the driven equipment. Solar is able to offer optional equipment and services, including the following, to facilitate the task of interfacing the gas turbine package with the driven equipment.

Shaft Coupling

The driver coupling hub may be furnished machined and ready for fitting to the shaft by others. The driven equipment coupling hub is pilot bored for machining by others, unless a driven equipment shaft end detail drawing is furnished at the time of order definition. A coupling guard can also be included.

Torsional Vibration Analysis

Solar is able to define operating speeds at which excessive vibration stress in the drive train might occur. Solar should be furnished, at the time of order definition, with mass elastic data for the shaft coupling and the rotating equipment elements, including polar moments of inertia and torsional stiffness. In lieu of mass elastic data, a drawing of rotating elements together with definition of materials may be used.

Lateral Vibration Analysis

Using the same data furnished for the torsional vibration analysis, Solar can define operating speeds at which stress in each piece of rotating equipment, including the turbine gearbox if required, and driven equipment, might occur due to excessive vibration. The data should be provided to Solar at the time of order definition. Once the analysis is completed, a written report is provided.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

6 Gearbox

6.1 General Description

If required, a gearbox (Figure 8) can be provided selected specifically for compressor set and mechanical drive applications. The gearbox uses few moving parts, providing high reliability and ease of assembly and disassembly. The gearbox is designed for continuous-duty operation and matches the output speed of the turbine or tandem compressor to the required operating speed of the driven compressor. Gear lubrication is provided by the package lube oil system. The gears can be serviced without removing the main case.

Depending on the application, the gearbox may be primary speed increasing or speed decreasing (between the gas turbine and the first or only driven compressor) or it may be inter-body speed increasing (between tandem compressors).

The gear unit is designed in accordance with American National Standards Institute/American Gear Manufacturers' Association (ANSI/AGMA) standards as described in Solar's specification ES 2238. The gear unit design includes a fabricated steel or cast iron housing, double helical precision hobbed and finished ground gear elements, and split steel-backed babbitt lined journal bearings on all shafts.

Figure 8. Typical Gearbox

6.1.1 Primary Speed-Increasing Gearbox

The primary speed-increasing gearbox will have a specific gear ratio and speed range. The gearbox increases the output speed of the turbine to the required operating speed of the driven compressor, optimizing the power turbine speed for each application. The gearbox output shaft direction of rotation is counterclockwise, when viewed from the aft (exhaust) end of the package looking forward.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

The gearbox is mounted on the driven skid and, together with the input shaft coupling, is lubricated and cooled by forced-fed lubricating oil from the turbine. Gearbox journal and thrust bearing temperatures are monitored by two simplex resistance temperature devices (RTDs) at each radial bearing and two per thrust face on the thrust bearing. The monitoring system is connected to one each of the radial bearing RTDs and one each RTD from each side of the thrust bearing, with the remaining circuits available as spares.

6.1.2 Inter-body Speed-Increasing Gearbox

The inter-body speed-increasing gearbox will have a specific gear ratio and speed range for the tandem compressor set application. The gearbox increases the output speed of the driving compressor to the required operating speed of the driven compressor. The gearbox output shaft direction of rotation is counterclockwise, when viewed from the aft (exhaust) end of the package looking forward towards the air inlet end of the package.

The gearbox is mounted on the driven compressor skid and together with the input shaft coupling, is lubricated and cooled by forced-fed lubricating oil from the turbine. Gearbox journal and thrust bearing temperatures are monitored by two simplex RTDs at each radial bearing and two per thrust face on the thrust bearing. The monitoring system is connected to one each of the radial bearing RTDs and one each RTD from each side of the thrust bearing, with the remaining circuits available as spares.

6.1.3 Primary Speed-Reducing Gearbox

The primary speed reducing gear will have a specific gear ratio and speed range. The speed-reducing gearbox reduces the output speed of the turbine to the required operating speed of the driven equipment, optimizing the power turbine speed for each application. The gearbox output shaft direction of rotation is counterclockwise, when viewed from the aft (exhaust) end of the package looking forward.

The gearbox is mounted on the driven equipment skid and, together with the input shaft coupling, is lubricated and cooled by forced-fed lubricating oil from the turbine. Gearbox journal and thrust bearing temperatures are monitored by two simplex RTDs at each radial bearing and two per thrust face on the thrust bearing. The monitoring system is connected to one each of the radial bearing RTDs and one each RTD from each side of the thrust bearing, with the remaining circuits available as spares.

Table 5. Gearbox Specifications

Approximate Weight

Gearbox 1100 kg (2400 lb)

Inspection and Overhaul Intervals

Major Inspection Interval 30,000 hours Overhaul Interval 100,000 hours

Compliance

American Petroleum Institute (API)

Ratings

American National Standards Institute/American Gear Manufacturers' Association (ANSI/AGMA)

Vibration Monitoring

Gearbox Acceleration Probe (Optional)

Applicable Engineering Specifications

Solar’s Engineering Specification ES 2021 Solar Turbine Package Head Loads and Oil Flows Solar’s Engineering Specification ES 2238 Parallel Shaft Gear Units

613 Compliant With Exceptions, Refer to Solar’s Standard List of Exceptions

2001-C95, 6025-D98, 6011-H98 and 6001-D97

Displacement Probes, X and Y axis (Optional) Displacement Probe, Axial (Optional)

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

7 Start System

7.1 General Description

The start system provides torque to initiate engine rotation and to assist the engine to reach a self-sustaining speed. The start system consists of either a direct-drive AC starter motor driven by a solid-state variable frequency drive (VFD) or an optional pneumatic start system.

7.2 Direct-Drive AC Start System

The direct-drive AC (DAC) start system consists of a squirrel cage, three-phase, acinduction motor with a solid-state variable frequency drive (VFD). The starter motor is mounted directly on the gas turbine accessory drive gearbox. The VFD regulates voltage and frequency to the starter motor for engine rotation as commanded by the Turbotronic 4 control system.

7.2.1 Functional Description

To begin gas turbine rotation, the VFD initially provides low-frequency AC power to the starter motor. The VFD gradually increases the speed of the starter motor until the gas turbine reaches purging speed. When purging is completed, the control system activates the fuel system. The speed of the starter motor is gradually increased until the gas turbine reaches starter dropout speed. The VFD then deenergizes the starter motor and the motor clutch assembly is disengaged.

7.2.2 Starter Motor

The starter motor (Figure 9) provides high breakaway starting torque and acceleration from standstill to starter dropout speed. The motor is standard frame size and is constructed to be explosion proof and flameproof. The motor includes an integral overtemperature protection thermostat connected to the Turbotronic 4 control system for hazardous area motor certification and protection. Separate cable/conduit entry points are provided for power connections, thermal protection wiring, and the space heater wiring. Starting power is transferred to the gas turbine via the reduction-drive gearbox and over-running clutch and shaft assembly.

7.2.3 Variable Frequency Drive

The VFD (Figure 9) is a motor speed controller that provides pulse-width modulated power with variable frequency and voltage to the starter motor. Controlled by the Turbotronic 4 control system, the VFD regulates voltage and frequency to the starter motor to control engine speed from standstill to starter dropout speed. The system is capable of performing up to six start attempts per hour, as well as extended purge cycles for heat recovery unit applications and engine wash cycles. The VFD cabinet is designed for installation in a non-hazardous location. Electrical disconnects and overcurrent protection devices are not provided.

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Figure 9. Typical Direct-Drive AC Starter Motor and Variable Frequency Drive

VARIABLE

FREQUENCY

DRIVE

MOTOR

CLUTCH

ASSEMBLY

GAS

TURBINE

AC POWER

CONNECTION

LINE REACTOR

RADIO

INTERFERENCE

FILTER

Figure 10. Typical Direct-Drive AC Start System

7.2.4 Power Wiring

The start system, (Figure 10) requires customer-furnished, three-phase AC input. Additional three-phase AC power wiring is required to connect the VFD to the starter motor. A start contactor is not required for VFD operation. A customer-furnished fused disconnect at the VFD input is recommended. Optional motor space heater wiring is available.

Table 6. Direct Drive AC Start System Specifications

Variable Frequency Drive

Optional Voltage Input Ranges 380 to 460 VAC, (48 to 62 Hz) Minimum Input Current

- 380 to 460 VAC Input 525 amps Voltage Output Range 0 to 460 VAC, (0 to 240 Hz) Maximum Line Distribution Capacity 1000 kVa Maximum Fault Current Capacity

30 000 amps, See Note (a)

Maximum Breakaway Amperage 383 amps Maximum Breakaway Torque 918 N-m (677 ft-lb)

Turbomachinery Package Specification Taurus 60 Compressor Set and Mechanical Drive

Variable Frequency Drive (cont.)

Power Factor 0.96 Efficiency 98% Minimum/Maximum Operating Temperature -10 to 40°C (14 to 104°F) Heat Rejection

- 380 to 460 VAC Input 1780 watts Input Fuse Rating 225 amp Approximate Measurements

- Height 85 cm (33.5 in.)

- Width 42 cm (16.6 in.)

- Depth 32 cm (12.7 in.) Approximate Weight 70 kg (155 lb)

Starter Motor

Motor Type Squirrel-cage Induction Motor Voltage Rating 380 AC, (0 to 133 Hz) Power 56 kW (75 hp) Operating Speed 0 to 4000 rpm Maximum Breakaway Amperage 205 amps Maximum Breakaway Torque 472 N-m (348 ft-lb) Minimum/Maximum Operating Temperature -25 to 60°C (-13 to 140°F) Space Heater Voltage 120 VAC, 60 Hz

240 VAC, 50 Hz

Approximate Measurements

- Length 75 cm (29.4 in.)

- Diameter 45.7 cm (18 in.) Approximate Weight

- AC Starter Motor Assembly 370 kg (820 lb)

Power Wiring

VFD to Starter Motors Power Cable Length

Solar’s Applicable Engineering Specifications

ES 1593

ES 1762

Solar’s Applicable Product Information Letters

PIL 149 Direct-drive AC Start Systems

Notes:

(a) Feeder circuits exceeding this limit require the use of an isolation transformer, line reactor, or

other means of adding similar impedance to limit fault current.

(b) Longer cable runs may require an onskid marshalling box and/or output line reactor.

Guidelines for NEC Compliance of Solar Product Lines: Class I, Group D, Division 1 and Division 2

Standards and Practices for Electrical Systems For Gas Turbine Packages Installed in Hazardous Areas (CENELEC Standards)

38 m (123 ft), See Note (b)

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