AC-734 ndash NORMAS PARA ENSAIOS DE COMPONENTES DE TURBINA A

GAacuteS -

Prof(a) Cristiane MartinsInstituto Tecnoloacutegico de AeronaacuteuticaDivisatildeo de Eng Aeronaacuteutica Dept de Propulsatildeo 112010

Na histoacuteria de conversatildeo de energia a turbina a gaacutes eacute relativamente nova A primeira turbina utilizada para geraccedilatildeo de eletricidade ocorreu em Neuchatel Suiacuteccedila 1939 desenvolvida pela Brown Boveri Company

O primeiro vocirco utilizando turbina a gaacutes ocorreu na Alemanha tambeacutem em 1939 com turbina desenvolvida por Hans P von Ohain Paralelamente Frank Whitte na Inglaterra inventou e desenvolveu turbina para aeronave nos anos de 1930 mas seu primeiro vocirco ocorreu somente em 1941

Voltando no tempo

Como a turbina a gaacutes se desenvolveu ao mesmo tempo tanto no campo da aviaccedilatildeo quanto para geraccedilatildeo de energia existiu uma proliferaccedilatildeo de diferentes nomes

Para geraccedilatildeo de energia eleacutetrica e aplicaccedilotildees naacuteuticas satildeo geralmente conhecidas como turbina a gaacutes motor turboeixo e tambeacutem motor turbina a gaacutes Em aplicaccedilotildees aeronaacuteuticas usualmente satildeo conhecidas como motor a jato e vaacuterios outros nomes dependendo da configuraccedilatildeo particular ou aplicaccedilatildeo tais como motor turbina a jato turbojato turbofan turboprop (se com heacutelice)

Atenccedilatildeo lsquorsquoTurbina a gaacutesrsquorsquo um pouco enganoso natildeo significa que o combustiacutevel utilizado seja gasoso O conjunto compressor-combustor-turbina da turbina a gaacutes (Fig 1) eacute comumente denominado gerador de gaacutes

turbina a gaacutesturbojatoturboeixo

Revendo conceitos

Turbina a gaacutes (mostrada ao lado) tem um compressor para comprimir o gaacutes succionado (usualmente ar) um combustor (ou queimador) para adicionar lsquoenergiarsquo ao ar pressurizado e uma turbina para extrair energia proveniente do gaacutes aquecido A turbina a gaacutes eacute uma maacutequina de combustatildeo interna que utiliza processo de combustatildeo contiacutenua Isto difere do motor a pistatildeo onde a combustatildeo eacute intermitenteFigura 1 Diagrama esquemaacutetico A) motor a jato aeronaacuteutico B) uma turbina a gaacutes (para uso em terra e em turboheacutelice)

Figura 2a Diagrama volume-pressatildeo do ciclo Brayton para uma unidade de massa de fluido de trabalho (ar por exemplo) mostrando entradas e saiacutedas de trabalho (W) e calor (Q)

Figura 2b Esquema da turbina mostrando pontos relativos ao ciclo Brayton do diagrama da Figura 2a

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Na histoacuteria de conversatildeo de energia a turbina a gaacutes eacute relativamente nova A primeira turbina utilizada para geraccedilatildeo de eletricidade ocorreu em Neuchatel Suiacuteccedila 1939 desenvolvida pela Brown Boveri Company

O primeiro vocirco utilizando turbina a gaacutes ocorreu na Alemanha tambeacutem em 1939 com turbina desenvolvida por Hans P von Ohain Paralelamente Frank Whitte na Inglaterra inventou e desenvolveu turbina para aeronave nos anos de 1930 mas seu primeiro vocirco ocorreu somente em 1941

Voltando no tempo

Como a turbina a gaacutes se desenvolveu ao mesmo tempo tanto no campo da aviaccedilatildeo quanto para geraccedilatildeo de energia existiu uma proliferaccedilatildeo de diferentes nomes

Para geraccedilatildeo de energia eleacutetrica e aplicaccedilotildees naacuteuticas satildeo geralmente conhecidas como turbina a gaacutes motor turboeixo e tambeacutem motor turbina a gaacutes Em aplicaccedilotildees aeronaacuteuticas usualmente satildeo conhecidas como motor a jato e vaacuterios outros nomes dependendo da configuraccedilatildeo particular ou aplicaccedilatildeo tais como motor turbina a jato turbojato turbofan turboprop (se com heacutelice)

Atenccedilatildeo lsquorsquoTurbina a gaacutesrsquorsquo um pouco enganoso natildeo significa que o combustiacutevel utilizado seja gasoso O conjunto compressor-combustor-turbina da turbina a gaacutes (Fig 1) eacute comumente denominado gerador de gaacutes

turbina a gaacutesturbojatoturboeixo

Revendo conceitos

Turbina a gaacutes (mostrada ao lado) tem um compressor para comprimir o gaacutes succionado (usualmente ar) um combustor (ou queimador) para adicionar lsquoenergiarsquo ao ar pressurizado e uma turbina para extrair energia proveniente do gaacutes aquecido A turbina a gaacutes eacute uma maacutequina de combustatildeo interna que utiliza processo de combustatildeo contiacutenua Isto difere do motor a pistatildeo onde a combustatildeo eacute intermitenteFigura 1 Diagrama esquemaacutetico A) motor a jato aeronaacuteutico B) uma turbina a gaacutes (para uso em terra e em turboheacutelice)

Figura 2a Diagrama volume-pressatildeo do ciclo Brayton para uma unidade de massa de fluido de trabalho (ar por exemplo) mostrando entradas e saiacutedas de trabalho (W) e calor (Q)

Figura 2b Esquema da turbina mostrando pontos relativos ao ciclo Brayton do diagrama da Figura 2a

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Como a turbina a gaacutes se desenvolveu ao mesmo tempo tanto no campo da aviaccedilatildeo quanto para geraccedilatildeo de energia existiu uma proliferaccedilatildeo de diferentes nomes

Para geraccedilatildeo de energia eleacutetrica e aplicaccedilotildees naacuteuticas satildeo geralmente conhecidas como turbina a gaacutes motor turboeixo e tambeacutem motor turbina a gaacutes Em aplicaccedilotildees aeronaacuteuticas usualmente satildeo conhecidas como motor a jato e vaacuterios outros nomes dependendo da configuraccedilatildeo particular ou aplicaccedilatildeo tais como motor turbina a jato turbojato turbofan turboprop (se com heacutelice)

Atenccedilatildeo lsquorsquoTurbina a gaacutesrsquorsquo um pouco enganoso natildeo significa que o combustiacutevel utilizado seja gasoso O conjunto compressor-combustor-turbina da turbina a gaacutes (Fig 1) eacute comumente denominado gerador de gaacutes

turbina a gaacutesturbojatoturboeixo

Revendo conceitos

Turbina a gaacutes (mostrada ao lado) tem um compressor para comprimir o gaacutes succionado (usualmente ar) um combustor (ou queimador) para adicionar lsquoenergiarsquo ao ar pressurizado e uma turbina para extrair energia proveniente do gaacutes aquecido A turbina a gaacutes eacute uma maacutequina de combustatildeo interna que utiliza processo de combustatildeo contiacutenua Isto difere do motor a pistatildeo onde a combustatildeo eacute intermitenteFigura 1 Diagrama esquemaacutetico A) motor a jato aeronaacuteutico B) uma turbina a gaacutes (para uso em terra e em turboheacutelice)

Figura 2a Diagrama volume-pressatildeo do ciclo Brayton para uma unidade de massa de fluido de trabalho (ar por exemplo) mostrando entradas e saiacutedas de trabalho (W) e calor (Q)

Figura 2b Esquema da turbina mostrando pontos relativos ao ciclo Brayton do diagrama da Figura 2a

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Revendo conceitos

Turbina a gaacutes (mostrada ao lado) tem um compressor para comprimir o gaacutes succionado (usualmente ar) um combustor (ou queimador) para adicionar lsquoenergiarsquo ao ar pressurizado e uma turbina para extrair energia proveniente do gaacutes aquecido A turbina a gaacutes eacute uma maacutequina de combustatildeo interna que utiliza processo de combustatildeo contiacutenua Isto difere do motor a pistatildeo onde a combustatildeo eacute intermitenteFigura 1 Diagrama esquemaacutetico A) motor a jato aeronaacuteutico B) uma turbina a gaacutes (para uso em terra e em turboheacutelice)

Figura 2a Diagrama volume-pressatildeo do ciclo Brayton para uma unidade de massa de fluido de trabalho (ar por exemplo) mostrando entradas e saiacutedas de trabalho (W) e calor (Q)

Figura 2b Esquema da turbina mostrando pontos relativos ao ciclo Brayton do diagrama da Figura 2a

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Figura 2a Diagrama volume-pressatildeo do ciclo Brayton para uma unidade de massa de fluido de trabalho (ar por exemplo) mostrando entradas e saiacutedas de trabalho (W) e calor (Q)

Figura 2b Esquema da turbina mostrando pontos relativos ao ciclo Brayton do diagrama da Figura 2a

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

THERMODINAMICA CICLO BRAYTON

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Acesse para baixar os arquivos de aulas

ftp1612415247Cristiane

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

COacuteDIGOS E PADROtildeES

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

COacuteDIGOS POR QUEcirc bull Fornecem orientaccedilotildees de projeto e definiccedilotildees

Exemplo Vibraccedilotildees Materiais Conexotildees bull Facilitar a construccedilatildeo e aquisiccedilatildeo bull Nenhum Coacutedigo lsquoprojetarsquo uma turbina a gaacutes bull Satildeo de natureza geral qualquer particularidade

pode exigir modificaccedilotildees

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Coacutedigos relevantes

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Coacutedigos comuns para aplicaccedilatildeo em Oil amp Gas

API 616 - Gas Turbines 1048766 API 617 ndash Compressors 1048766 API 614 ndash Lube Oil System 1048766 API 670 ndash Machinery Protection 1048766 API 613 ndash Load and Accessory Gear 1048766 API 677 ndash Accessory Drive Gear 1048766 API 671 ndash Flexible Couplings 1048766 NFPA 70 Electric Code 1048766 ASME PTC-22 Gas Turbine Testing 1048766 ASME PTC-10 Compressor Testing 1048766 ASME B133 - Gas Turbines

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

outros coacutedigos internacionais

ISO Codes (ISO 3977 - Gas Turbines) IECCENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications

ndash Upstream Mostly APIfirm ndash Midstream Some APIflexible ndash Downstream Mostly APIvery firm

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API

American Petroleum Institute US Petroleum Industry Primary Trade Association ndash 400 Member Companies ndash Covers all Aspects of Oil amp Gas Industry ndash Accredited by ANSI (American National StandardsOrganization) ndash Started Developing Standards in 1924 ndash Maintains about 500 Standards ndash API Codes are Widely Referenced by EPA OSHAOPS MMS BLM and Many Local Codes

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API - Filosofia

ndash Melhora na seguranccedila ndash Melhora de desempenho ambiental ndash Reduzir custos de engenharia ndash Melhora de intercacircmbio entre

equipamentos ndash Melhora na qualidade do produto ndash Menor custo de equipamento ndash Allows for Exceptions for Reason

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API Standards com propoacutesito de compra Fornece meios para comprador normalizar

as cotaccedilotildees obrigando os vendedores a cotar similares escopos

Fornecem linguagem comum e ajusta regras entre vendedor e comprador para reduzir desentendimento por exemplo define eficiecircncia procedimentos de testes data sheets

Claramente declara no iniacutecio que Exceccedilotildees satildeo permitidas se conduzirem a melhora ou ofertas teacutecnicas mais seguras

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API

Turbinas a gaacutes no setor oil amp gas API 616 eacute a fundamental para quase todos especificaccedilotildees de compra

bull API 617 eacute utilizada para aplicaccedilotildees criacuteticas de compressor centriacutefugo (alta pressatildeo e alta energia)

bull NFPA 70 coacutedigo eleacutetrico para locais perigosos eacute exigecircncia fundamental na API

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

APIStandard Topics

Definitions

ndash ISO Rating Normal Operating Point Maximum Continuous Speed Trip Speed etc

1048766Mechanical Integrityndash Blade Natural Frequencies Vibration Levels

Balancing Requirements Alarms and Shutdowns

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

APIStandard Topics Design Requirements and Features

ndash Materials Welding Accessories Controls Instrumentation InletExhaust Systems Fuel Systems

Inspection Testing and Preparation for Shipmentndash Minimum Testing Inspection and Certification

Documentation Requirements

Does not cover government codes amp regulations

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API

API Data Sheets

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616

Gas Turbine

Note API 616 does not apply to Aero-Derivative Gas Turbines ndash Only Industrial

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 Intro amp Definitions

10 Alternative Designs 11 Alternative designs allowed Emphasized in API Foreword

20 References 21 All reference standards are automatically included Allmanufacturers take exception to this

30 Definitions 317 ISO defined as T=15C P=10133 bar RH=60

319 Maximum allowable speed Speed at which unit can safely operate continuously per manufacturer

322 Maximum continuous speed 105 highest design speed

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Definitions

326 Normal Operating Point Usually the performance guarantee (heat rate power) point for gas turbine Defined by speed fuel and site conditions

338 Rated speed Power turbine speed at which site rated power is achieved

342 Site rated conditions Worst site condition at which still site rated power can be achieved Provided by User

345 Site rated power The maximum power achievable at site rated conditions Provided by Manufacturer Note Unless specifically stated by purchaser this is not a guarantee point

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

350 Turbine trip speed Speed where controls shut unit down

351 Unit responsibility Prime package contractor to user

40 Basic Design 411 Equipment designed for 20 years and 3 years of

uninterrupted service Hot section inspection every 8000 hours

412 Gas turbine vendor has unit responsibility unless otherwise specified

415 Speed ranges Two-shaft 50-105 rated speed Single-shaft 80-105 rated speed

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

4114 On-skid electric shall meet NFPA 70

4116 Most gas turbine internals shall be exchangeable at site Disqualifies most aeroderivate gas turbines

4117 Unit shall meet performance acceptance criteria both in the factory and at site Most manufacturers take exception to site performance guarantee unless field test is performed

4118 Vendor shall review customers installation drawings

4121 Gas turbine must meet site rated power with no negative tolerances

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

421 Casing hoop stresses must meet ASME Section VIII

427 Openings for borescope inspection must be provided for entire rotor without disassembly

429 Field balancing (if required) without removal of casing is OK

431 Combustors must have two igniters or igniter and cross-tubes

432 Requires temperature sensors in each combustor Not feasible in most gas turbine designs T5 (2-shaft) or T6 (1-shaft) normal

437 Fuel Wobbe index range must be indicated in proposal

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

The combustor casing is welded form solid machined and formed sheet titanium() components Whatrsquos shown here is one of the spark plugs with the pilot burner fuel fitting and the fuel drain port in the lower right of the picture

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

The fuel manifold supplies diesel or kerosine to the twelve vaporiser sticks To provide equal fuel quantities to all sticks the fuel has to pass calibrated resirictor plates in each of the injectors

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Except for the swirl vanes around the fuel nozzle on the top this combustor consists completely of sheet metal

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Iacutendice de Wobbe

Wobbe desenvolveu seu iacutendice em 1926 ao estudar o fenocircmeno da combustatildeo de gases injetados atraveacutes de um orifiacutecio

Este iacutendice se relaciona ao fluxo de energia teacutermica supondo-se inalteradas as condiccedilotildees de pressatildeo de suprimento do gaacutes e o diacircmetro do orifiacutecio atraveacutes do qual o gaacutes flui

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Iacutendice de Wobbe

O iacutendice de Wobbe decorre da seguinte equaccedilatildeo Taxa de energia teacutermica (kcals) = poder caloriacutefico do gaacutes (kcalNm3) x vazatildeo volumeacutetrica do gaacutes (Nm3s)

p

AkHQ gaacutes

Q = taxa de energia teacutermica

Hgaacutes = poder caloriacutefico do gaacutes

A = aacuterea da seccedilatildeo transversal do orifiacutecio de gaacutes no queimadork = coeficiente de descarga do orifiacuteciop = pressatildeo manomeacutetrica de suprimento do gaacutes = massa especiacutefica do gaacutes

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Iacutendice de Wobbe

A foacutermula pode ser escrita como

d

pAkHQ argaacutes

ar = massa especiacutefica do ar

d = densidade do gaacutes combustiacutevel em relaccedilatildeo ao ar

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Iacutendice de Wobbe

Wobbe definiu seu iacutendice como

d

HW

gaacutes

de tal maneira que

pWAkQ ar

Vecirc-se claramente que dois gases diferentes produziratildeo no mesmo queimador com a mesma pressatildeo manomeacutetrica a mesma taxa de energia teacutermica se os iacutendices de Wobbe forem os mesmos

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Iacutendice de Wobbe

Um dos criteacuterios adotados para que dois gases sejam intercambiaacuteveis eacute que seus iacutendices de Wobbe sejam aproximadamente os mesmos dentro de um intervalo de 5

Assim para conseguir um iacutendice de Wobbe adequado utilizam-se misturas de gases na substituiccedilatildeo Como exemplo citamos uma mistura de gaacutes natural e ar para queimar em equipamento ajustado para gaacutes de coqueria

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

44 Casing Connections Section outlines good design practices Most manufacturers are OK

4512 Shafts shall be single piece heat treated steel Stacked rotors with a tie-bolt are not allowed Difficult to meet for most manufacturers and not critical if rotor has been operationally proven

4521 Rotor shall be designed for overspeed up to 110 of trip speed

4522 All rotor components must withstand instantaneous loss of 100 shaft load (eg coupling failure)

46 Seals Renewable seals at all close clearance points

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

turbine rotor

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

rotor components

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Figura 28 ndash Ilustraccedilatildeo do diacircmetro inducer e exducer nos rotores do compressor e turbina

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

The compressor diffuser consists of straight vanes and a set of flow straightening radial vanes at the circumference It has about twice the diameter of the compressor wheel Consequently the efficiency should be quite good

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

compressor coverbearing housing assembly This is one of the most complicated parts of the whole turbine engine because it contains the complete lubrication system for the single hydrodynamic and the two hybrid ball bearings

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Bearing-housing

httpwwwtechnologie-entwicklungdeGasturbinesEngine_Expositionengine_expositionhtml

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Notice the cute airfoil shape of the vanes This is the maximum exhaust flow - minimum charge pressure - position

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

47 Rotordynamics Follow good design practices for progressive balancing with residual unbalance check High speed balancing is discouraged

4811 Hydrodynamic radial and thrust bearings are preferred Thrust- Tilt pad Radial Tilt pad or sleeve

4825 If rolling element bearings are used they must meet 50000 hours of continuous operation

4852 Bearings Labyrinth type seal required Lip seal not acceptable

4853 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Mapa do compressor

O mapa do compressor descreve as caracteriacutesticas particulares de desempenho de um compressor incluindo a eficiecircncia vazatildeo a capacidade de aumentar a pressatildeo e a rotaccedilatildeo

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Mapa do compressor

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

A relaccedilatildeo de pressatildeo eacute definida como a divisatildeo entre a pressatildeo de saiacuteda do compressor pela pressatildeo na sua entrada ambas em condiccedilatildeo absoluta

1

21

P

PRPcomp

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Mapa do compressor - Linha de Surge

Bombeamento (ou Surge na liacutengua inglesa) eacute o limite esquerdo do mapa do compressor Operar agrave esquerda desta linha representa uma regiatildeo de instabilidade

Esta regiatildeo eacute caracterizada pela vibraccedilatildeo suave e flutuaccedilatildeo de pressatildeo no compressor

A contiacutenua operaccedilatildeo nesta regiatildeo pode levar a quebras prematuras de turbo-compressores devido agraves altas cargas axiais

O surge geralmente eacute esperado em condiccedilotildees onde o motor estaacute em rotaccedilotildees baixas e a plena carga assim pode ser um indiacutecio de que o tamanho do compressor eacute grande

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Mapa do compressor - Linha de Choke

A linha de estagnaccedilatildeo (choke na liacutengua inglesa) eacute o limite agrave direita do mapa do compressor eacute o ponto de maacutexima vazatildeo do rotor

A linha de choke eacute normalmente definida pelo ponto onde a eficiecircncia do compressor se torna muito baixa

Aleacutem da raacutepida queda de rendimento do compressor para aleacutem deste ponto a relaccedilatildeo de compressatildeo eacute muito baixa

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

Mapa do compressor - Ilhas de eficiecircncia

As ilhas de eficiecircncia satildeo regiotildees concecircntricas nos mapas que representam a eficiecircncia do compressor em qualquer ponto no mapa

A ilha menor perto do centro do mapa eacute a ilha de maior eficiecircncia

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Engine

492 Synthetic lube oil is OK

495 Integrated or separate lube GT Compressor oil system OK

497 Lube oil system must meet API 614 Note Lube oil tank typically integrated into skid

410 Materials Follow good design rules Purchaser may require 100 radiography magnetic particle inspection or liquid penetrant inspection on all welds

4113 A SS nameplate to include rated performance and conditions critical speeds maximum continuous speed overspeed trip and fuel type

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Accessories

50 Accessories 5111 Electric pneumatic electro-hydraulic gas engine

steam turbine all acceptable starterhelper motors Starter drivers are uncoupled after startup helper drivers remain coupled

5117 Starter motors must be supplied with all necessary gears couplings and clutches

5121 Starters shall be rated 110 of starting torque required Vendor to supply torque curves

513 Turning gear Device to periodically rotate to avoid shaft deformation Generally not required on smaller turbines

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616- Accessories

521 Vendor to supply accessory gear for starting auxiliary equipment (LO pump) Vendor to also supply separate load gear if required

All gears shall meet API 613 Accessory gears shall be rated for 110 of required load

522 Vendor to supply all couplings and guards for load and accessory shafts Couplings to be sized for maximum continuous torque and meet API 671

53 Gas turbine to be supplied on single mounting plate (baseplate) Typically interpreted to allow for skid mounting Skid to be designed to limit worst case shaft alignment change to 50 micrometers

532 Single piece baseplate preferred Baseplate shall extend under driven equipment

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash AccessoriesControls 5324 Skid to permit field leveling

5412 Controls and instrumentation shall be suitable for outdoor installation Usually not necessary or practical

5413 GT instruments and controls shall meet API 670

5414 GT control system must provide for safe startup operation and shutdown of gas turbine

5416 Unit shall continue to operate for specified time after AC failure To overcome delay of emergency power startup

5421 Automatic start to require only single operator action

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash Controls

5422 Control system to completely purge unit prior to startup

5434 Load control to limit driven equipment speed to 105 rated speed

5441 Alarmshutdown system to be provided to protect unit and operator Both Normal and Emergency (Fast) shutdown (ie cut of of fuel supply) must be available

5443 Fuel control must include separate shutoff and vent valves separate from fuel control valve with local and remote trip

54481 Alarm and shutdown switches shall be separate Often not practical (eg flame detector axial thrust position

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Alarms

a - Optional

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Sensors

54483 Alarm and trip settings not adjustable from outside housing Not relevant with modern control systems

5449 All instruments (other than shutdown switches) shall be replaceable without shutting unit down Not practical on many switches

54511 Off-skid or on-skid control system to be supplied with unit

54511 Any on-skid control system must meet hazardous area requirements (NFPA70)

5462 On-skid electric systems must meet NFPA 70

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash InletExhaust

547 Instrumentation The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation Manufacturer will often cross out line to indicate noncomplianceVendor must include in proposal full list of instrumentation API 670 governs basic requirements for temperature and vibration sensors

5531 Air inlet and exhaust system including inlet filter inletexhaust silencers ducting and joints to be provided by vendor

5533 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power

5534 Inletexhaust system design life is 20 years

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Anciliaries

5422 Bolts rivets or fasteners are not permitted in inlet system

5539 A gas turbine compressor cleaning system must be provided

5544 Inlet Filter System requires walkways and handrails Not necessary for very small units

555 InletExhaust Silencer Internals to be Stainless Steel External Carbon Steel

573 Unit must be supplied with gas detection system fire detection system and fire suppression system to meet NFPA Fire suppression shall be automatic based on thermal detection Typical Thermal thermal gradient LEL and flash detector CO2 for suppression

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash EnclosureFuels

575 When enclosure is supplied it must be weatherproof and include fire detectionsuppression ventilationpurging lights and doors and windows

5812 Gas fuel system Must include strainer instrumentation manifolds nozzles control valve shutoff valve pressure regulator and vent valve

5813 Fuel gas piping must be stainless steel

5814 Liquid fuel system Must include pump atomizing air two shutoff valves instrumentation control valves flow dividers nozzles and manifolds Newer systems employ variable speed pumps instead of control valves

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Fuels

58152 If dual fuel system is provided it must allow bumpless bidirectional transfer

58222 Vendor must review customerrsquos fuel supply system

5824 Heating value of fuel cannot vary by more than plusmn10

5842 Purchaser must specify required site emissions levels for NOx CO UHC et al

60 Inspection Testing and Preparation for Shipment Inspections Standard machinery type includes materials mechanical Radiographic ultrasonic magnetic particle dye penetrant etc

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Testing

6323 Hydrostatic tests Vessels and piping per ASME Section VIII (15 times rated pressure)

633 Mechanical Running Test 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inletexhaust system) operates within vibration and operational control limits Contract coupling should be used Rotordynamic signature and vibrations must be recorded Compliance with these requirements is critical

634 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 - Testing

6341 Optional Performance Test Unit full load tested to PTC 22

6342 Optional Complete Unit Test Similar to Mechanical run test but to include driven equipment

6343 Gear must be tested with unit during mechanical run test Other optional test Sound level Auxiliary Equipment Fire Protection Control response Spare Parts

6346 If unit fail mechanical run test complete disassembly is required

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash Vendor Data

64 Preparation for Shipment Short term ndash plastic wrapping Long Term ndash crating surface anti-corrosion treatment nitrogen fill of all vessels

70 Vendorrsquos Data Strictly follows Data Sheet requirements Manufacturers must cross out line if they do not meet API Minimum must contain performance maps performance calculations mechanical hydraulic layout and electrical drawings PampIDs test and inspection results as-built parts lists operation and maintenance manuals installation manual and technical data

API 616 ndash Vendor Data

API 616 ndash Vendor Data