PGT 25+ START UP SEQUENCE

PRESENTED BY: AHMED TAREK EL-SHEIKH

TURBOMACHINERY TEAM

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 HMI
Human Machine Interface

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 PGT 25+ START UP SEQUENCE

Safety precautions
1- PPE.
2- Check if there is any working permit is opened on the train.
3-Check if the installations and surrounding area are free of any obstacles
(Scaffolding and insulations).
4- Check the position of push buttons of drawers.

36
 PGT 25+ START UP SEQUENCE
Pre-start Procedures
1- Check the position of fuel gas manual valve.
2- Open synthetic oil manual valve.
3- Open run down manual valve.
4- Start mineral oil AC pump.
5- Open seal gas valve, Heater ON until 72 degree.
6- Check that N2 pressure not lower than 3.5 bar. (why)
If lower than 3.5 bar, oil pumps deactivated because oil will
penetrate dry gas seal.
7- Check enclosure doors and CO2 valves.

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PGT 25+ START UP SEQUENCE
Modes of operation

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 PGT 25+ START UP SEQUENCE
Modes of operation
OFF: No kind of sequence can be run because it means that the machine is not ready to start; this position can be activated when machine is
stopped.

CRANK: the procedure allows the completion of axial compressor purge, after the process valve sequence completed, (2100 rpm).
Then other phases can be initiated if the Master Selector is switched on AUTO, MANUAL or REMOTE position.

IDLE: The ignition phase is allowed, the flame is detected and the turbine can arrive to the idle condition. Then other phases can be initiated if
the Master Selector is switched on AUTO, MANUAL or REMOTE position. The Gas Generator can stay at idle speed for 30 minutes at most.

MANUAL: the start-up procedure cannot be interrupted, and at the end of it the load is under manual control through RAISE and LOWER HMI
push button.

AUTO: the start-up procedure cannot be interrupted, and at the end of it the load is under external control.

REMOTE: the situation is similar to AUTO one, but the start command is remote.

CALIBRATION CRANK: only calibration crank operations are allowed. During this state the gas generator speed is maintained at crank speed value
(1200 rpm). During this state it is possible to operate the fuel metering valve calibration procedure. Process lines (anti-surge) are not purged.
Process valves position are not checked; they can be in shutdown condition.
Give me access to calibrate VSV degree.
Give me access to check bleed valve after maintenance.

WATER WASH: The off-line and online water wash is available (1200 rpm).

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PGT 25+ START UP SEQUENCE
Start check

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 PGT 25+ START UP SEQUENCE

Start-up Sequence

48
Alarm/Trip Override
Prior to, and during, the start-up sequences, certain alarm and trip functions have to be
inhibited/overridden to prevent unnecessary/false alarms being annunciated; these are:

- Mineral lube oil header pressure low alarms (10 second after the auxiliaries start command).
- Mineral lube oil header pressure low low trip.
- Mineral lube oil header pressure to power turbine low.
- Fuel gas pressure low alarm (prior to crank).
- Seal gas vent flow low (prior to end of sequence).
- GG synthetic oil pressure low alarm and low low trip (prior to GG speed reaching 4,600 rpm).
- Loss of Flame trip (prior to light-off).
- GG vibration high alarm and high high trip are disabled prior to GG speed reach Idle speed 6,800 rpm.

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1- Automatic auxiliary check
-DC Pump.
-Oil Vapor Separator.
-Ventilation Fan.
-Mineral oil coolers
TURBINE STATUS: AUX. Check

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2- Enclosure purge
It takes 3 minutes.
TURBINE STATUS: Process on

3- Open back-up fuel valve

Why not main ?
TURBINE STATUS: Process on

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- If main compressor is depressurized

Purge for compressor stages:

- Close AS valves.
- Open pressurizing valve XV-7927 A (Suction
equalizing valve).
- Open blow off valve.
- Time delay (defined by customer) to purge the
compressor line.
- After purge time is elapsed AS line purge is enabled.

Purge for AS lines:

- Open AS lines (FV-7127 A and FV-7131 A).
- As soon as AS valves are closed a time delay starts
(defined by customer) to purge the AS lines.

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Set correct valves position for ready to crank:
- AS valves (FV-7127 A and FV-7131 A) shall be in
open position.
- Blow down valve XV-7937 A is closed and Discharge
Pressurizing valve XV-7944 A is open.
- Suction valve XV-7926 A is open when differential
pressure PDT-7253 A is lower than a threshold.
- Suction Pressurizing valve XV-7927 A is closed.
- Discharge valve XV-7943 A is open when differential
pressure PDT-7264 A is lower than a threshold.
- Discharge Pressurizing valve XV-7944 A is closed.

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4- Open warm up valve
Until fuel temp. reach 40 degree.
TURBINE STATUS: Process on

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5- Open suction & discharge equalizing valve
Until delta P < 0.5 bar
TURBINE STATUS: Process on

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6- Start starting motor
Warm up valve closed.
Pressure of hyd. Pump is 300 bar
TURBINE STATUS: acc. to crank

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7- Raising speed of GG to 2100 rpm
For 120 sec at 2100 rpm
To purge the combustion chamber for ignition.
TURBINE STATUS: purge for ignition

8- Open shut off valves & spark plug

TURBINE STATUS: ignition

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9- System start mineral oil cooler

After normal ignition

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10- Raising speed
Started raise speed to 4500 rpm (starter out) and speed continue
raising until reach 6800 rpm for GG and 1930 rpm for PT.
TURBINE STATUS: step to idle

11- Air circulation

5 min. at 6800 GG speed to circulation air in GG (hot start).
10 min. at 6800 GG speed to circulation air in GG (cold start).
TURBINE STATUS: engine warm up

12- Raising PT speed

Raise PT speed up to 70 % (4300 rpm)

TURBINE STATUS: acc. To PT crank

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13- On Load

- Raising speed to 99% PT

TURBINE STATUS: on load control

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14- Loading
Close anti-surge valve regarding to surge
point.

TURBINE STATUS: on load control

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 PGT 25+ START UP SEQUENCE

After start up checks

1- Check vibration on HMI.
2- Check for any leakage in enclosure.
3- Monitoring anti-surge point on HMI.
4- Select OFF mode on HMI.
5- Check the following Readings:
- Mineral oil pressure : 1.6 bar
- Mineral oil temp. : 58 degree
- Synthetic oil pressure : 6 bar
- Synthetic oil temp. : 55 degree
- Fuel gas pressure : 38 bar
- Fuel gas temp. : 70 degree
- Seal gas pressure : 58 bar
- Seal gas temp. : 81 degree

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Flow Chart

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 Start
Sequence
1- Ready to start
yes
Any SD, ES,
ESN, DM, SI
active?

Sequencer start check: no

permissive from production. no
Core start check: GG, PT IN
STOP
temp. sensors of T48 (loss 4 or more from 8). CONDITION?

CDP loss of both sensors.

yes

no
Core and
sequencer
permissive
ok? (1)

yes
Process valve
no
ready to start
AUX
PERMISSIVE
And OK?

Customer ready yes

to start
And

Operative
mode
selection 66
 - Start oil tank temperature not high high, or not sensor in fault.
Prior to train start-up all start-up permissive must be - Run-Down tank level not low, or not sensor fault (Permissive to
confirmed, these will include: crank).
- Engine lock out not verified. - G.T. Enclosure doors not open.
- OFF mode not selected. - G.T. Enclosure ventilation dampers open.
- Any Shutdown, Trip (Emergency shutdown pressurized, no - GT Enclosure fire UV detectors not in alarm, or not sensor in fault.
- G.T. Enclosure temperature not high.
motoring), Deceleration to minimum load, Step to idle
- Gas in turbine enclosure sensors not in alarm, or not sensor in
conditions not verified. fault.
- Set-Point of GG and PT speed regulators at minimum value. - CO2 main battery bank level indication limit switches not low.
- GG Speed < 350 RPM - CO2 standby battery bank level indication limit switches not low.
- Fuel gas metering valves driver not in fault. - CO2 operated valve limit switches open.
- Fuel Gas Shut-Off valves closed. - Mineral lube oil tank level not low, or not in sensor fault.
- Fuel gas supply temperature not low, or not sensor in fault - Mineral lube oil tank temperature not low, or not sensor in fault.
(Permissive to crank). - Mineral lube oil header pressure not low, or not sensor in fault
(Permissive to crank).
- Flame detector circuit OK not in fault.
- Fire fighting system ready and in auto mode.
- Fuel Gas Warm-Up Valve closed. - Fire system common fault not true.
- Synthetic oil tank level not low, or not sensor in fault. - Seal gas inlet balancing line pressure not low (Permissive to crank).
- Synthetic oil tank temperature not low, or not sensor in fault. - Seal gas downstream heater temperature not low (Permissive to
- Synthetic oil manual valve open. crank).
- Differential pressure from hydraulic filter PDIT not in fault. - Fault for each motor not true.
- Starter suction line valves open. - Vibration monitor fault alarm not true.
- Over speed monitor fault alarm not true.
- Process Anti-surge Valves Open. 67
 Start

2- operative mode selection

off
Master
selector
-crank
-idle
-manual
-auto
-remote
-calibration crank
-water wash
Remote Master
selector

no

And
Customer start
yes Start push
command button on
HMI

Master
selector
-crank
-idle
-manual
-auto
-remote

Offline water Calibration

Run
wash crank
sequence
sequence sequence

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 Start
3- Run sequence

Emergency equipment test

Auxiliaries test: active

- DC pump activated. no
- Ventilation system activated.
Emergency
- Mineral oil vapor separator activated. pump test timer
passed?
- Mineral oil coolers activated.

Start auxiliaries

Start process valve no

position

Auxiliaries start
passed?(1)

Compressor
pressurized?
yes

no Master protective signal enabled

Purge sequence
Open fuel block valves/
no close vent ?
And
Valve
position ok? Warm up sequence

Crank
sequence
69
 Start

4- Crank sequence
no
Aux ready to
crank?

yes

Starting system activation

In case it at crank mode then
become at manual mode
no
no
GG speed
GG above
above crank
zero speed ?
speed?

yes no
Abort if crank speed
is not reached in 60
NGG at sec
Start purge timer crank
Purge_T=V*Q speed? 2100
rpm

yes

CRANK
no

Purge timer
elapsed?

And

yes

Ignition and
warm up
sequence 70
5- ignition and warm up sequence Start

Open shut off / close vent Aux (fuel gas

skid) ready
valve to fire?

yes
no
no
Flame
yes
detected? Core and
sequencer
ready to
fire?

yes
crank

Firing time
elapsed? Master
selector Auto
Remote
yes Manual
idle

Close shut off / open vent -lube oil cooling system activated Open metering valve
valve -accelerate to idle speed
Close metering valve

no
NGG at 4500
Fail to purge sequence rpm ?

yes
Stop starting device
Stop starting device

2
1
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 1
2

no
Ventilation timer
NGG at idle
speed?
(120 min) activated
(6800 rpm)

yes
no
WARMUP
Time
expired?
-30 min until oil is heated. no
-Operative speed sequence at 70% PT. Idle time
(5 min)
elapsed? yes

Ventilation system stop

no
Max idle
time yes
(30 min)
elapsed?

no Normal shut Fuel block valve closed

down sequence fuel vent valve opened
idle
Master
selector

-manual End End

no -remote
-auto
Synthetic oil
temp (35 c)
above required
value?

Acceleration
to operative
speed
sequence
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 Start

6- Acceleration to operative speed

Accelerate PT to min.
operative speed

PT at min
no
operative
speed ?
(3050 rpm)

yes

Turbine start sequence

ended / ready to load

no
Aux ready to
load ?

yes
Speed
AS control
control Turbine is running on
load control

AS
Master
selecto
selecto
r on
r Auto HMI manual
Remote
Control LP
LP shaft speed shaft speed by Manual AS
AS valve under
remote control raise/lower open/close
auto control
speed on HMI valve

End End 73
sequence sequence
 start

7- Water wash sequence

- Turbine offline water wash
sequence initiated.
- Start aux.

Mineral lube oil system

activated

no
Operated at 1200 rpm. Aux start
passed?

Master protective signal enabled

Starting system activated

no NGG at
offline WW
speed (1200
rpm)
yes

Offline WW (40 min)

Stop offline WW

Stop starting device

End
Aux min. lube oil deactivated sequence
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 start

8- Calibration crank sequence

- Turbine Calibration Crank sequence
initiated.
- Start aux.

Mineral lube oil system activated

no
Aux start
passed?

Master protective signal enabled

Starting system activated

no NGG at
calibration
crank speed
(1200 rpm)
yes

- Calibration crank (40 min)

- Fuel calibration sequence allowed

Stop calibration crank

Stop starting device

End
Aux min. lube oil deactivated sequence

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 Start
9- Deceleration to minimum load
On load control

DM request
from aux?

Deceleration to Min. Load conditions: yes

no
- Synthetic oil supply temperature high high.
- Axial compressor inlet temperature both sensors in fault. DM request
from core or

- Fuel Gas Supply Pressure low. sequencer?

- Inlet screen differential pressure high high. yes

- Combustion air Inlet screen differential pressure high high. Decelerating PT toward
min operative speed
- Fuel Gas Temperature TE-0101 A, TE-0101 B both sensors in fault.
no
PT at min
operative
speed?

yes
-Auto
Remote Master -Manual
selecto
r
no
Start
Customer start And push
command button on
HMI?

6
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 Speed
AS control
control
6

AS
Master
selecto
selecto
r on
r Auto HMI manual
Remote
Control LP
LP shaft speed shaft speed by Manual AS
AS valve under
remote control raise/lower open/close
auto control
speed on HMI valve

End End
sequence sequence

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 start

10- Step to idle sequence Current operative condition with

NGG above idle speed

SI request
from aux?
SI request from core and sequencer
yes
- High vibration on GG and PT. no
no
SI request
- High exhaust temp. from core and
sequencer?
(1)

yes
PT unloading
Load controller
stop
Decelerating GG to idle speed

no
no
PT under min
operative AS regulator stop – opening
Max idle speed? AS valve with safety
time yes protection ramp (30% / sec)
elapsed?
(30 min)
no
Normal GG at idle
no no shutdown speed?
sequence
Restart
action? yes

no yes
yes SI vibration
active?
Emergency shut down no
Accelerating to
operative speed motoring
sequence

end 78
Step to idle conditions:
- GG accelerometer vibration high high (after 10 s if the vibration doesn’t stop theEmergency shutdown no
motoring sequence will be activated).
- PT accelerometer vibration high high (after 10 s if the vibration doesn’t stop theEmergency shutdown no
motoring sequence will be activated).
- Power turbine exhaust temperature high high.
- Power Turbine bearings RTD’s high high.
- PT exhaust temperature high high.
- FV-0104 metering valve downstream pressure PIT-0104 A, PIT-0104 B both sensors in fault.
- FV-0107 metering valve downstream pressure PIT-0107 A, PIT-0107 B both sensors in fault.

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 -Auto
Start -Manual
-WW
11- shut down sequence -IDLE
-Crank
-Calibration crank
Remote Master
selector

Customer no no
SD request from sequencer stop?
SD request
HMI stop?

- Temp. sensor fault on gear box, synthetic oil, PT from aux yes

exhaust, journal bearing.

SD request yes
from
process
no
SD request
no from
sequencer
(1)
yes

Shut down in progress- PT Stop load controller

unloading
no AS valve open according
to ‘slow opening’ ramp
no PT at min (0.5% / sec)
operative
speed

Restart AS yes
action? Stop AS regulator completely End
open
yes yes
no
reloading - Decelerating GG to idle. Opening AS
- Aux mineral oil pump valve (30% / sec)
activating.

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3 80
 3

Speed
AS control no
control
6 GG at
idle
speed?

AS yes
Master
selecto
selecto
r on
r Auto HMI no no Cool stop
manual idle time
Remote
elapsed?
Control LP
LP shaft speed shaft speed by Manual AS yes
AS valve under Restart
remote control raise/lower open/close
auto control action?
speed on HMI valve
- Shutoff and metering valves
End End
yes closed, vent valve opened
sequence sequence
Acceleration
to operative
speed Cool down
sequence

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Shutdown conditions: <1>
- Power Turbine Wheel space fist stage temperature high high, or fault of both sensors.
- Power Turbine Wheel space second stage temperature high high, or fault of both sensors.
- Synthetic oil supply temperature fault of both sensors.
- A.G.B. scavenge oil temperature fault of both sensors.
- “A” sump and TGB scavenge oil temperature fault of both Sensors.
- “B” sump and TGB scavenge oil temperature fault of both Sensors.
- “C” sump and TGB scavenge oil temperature fault of both Sensors.
- Power turbine bearing 1 temperature fault of both Sensors.
- Power turbine bearing 2 temperature fault of both Sensors.
- Power turbine thrust bearing active side temperature fault of both sensors.
- Power turbine thrust bearing inactive side temperature fault of both sensors.
- Turbine air Inlet filter differential pressure high high or fault of one or two sensors.
- GT Enclosure heat raise detector three or four sensors fault.
- Exhaust compartment heat raise detector one or two sensors fault.
- Shutdown HMI push-button.
- Remote stop command.
- Gas generator exhaust temperatures fault of 3 or 4 adjacent sensors.
- Gas generator exhaust temperatures Fault of more than 3.
- Gas turbine exhaust temperatures Fault of more than 3.

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 start

12- Emergency shut down Current operative

condition

ES command
from process
ES/ESN
request from
process?

no Customer trip
motoring /
yes ES/ESN pressurized
ES / ESN request from core and sequencer? request from
customer?
- Fuel metering system ES/ESN
no
- Fault or critical condition
- High temp on journal bearing. yes
ES/ESN request
from aux?

no no

ES/ESN request
from core and
sequencer?(1)

yes

Close shut off valves/ open Load control Pressurized Opening AS valve with safety
vent valves stop ESD activated protection ramp (30%/sec)

Close metering valve

no
PT at min
operative
speed ?

yes
Cool down 83
sequence
 start

no
13- motoring sequence after NS or low pressure ES NGG under
300 rpm?

(T48<620 degree c) yes

Start lock out
timer (6 min)

PT completely stopped: power turbine speed is continuously checked Lock out timer yes
elapsed?
during motoring. If completely stopped condition is left, motoring is
System in engine
no
aborted and engine lockout is immediately operated. lockout (4 hrs)
no
Motoring abort conditions: PT completely
stopped?
-low mineral oil pressure yes
End

-PT not stopped during motoring no Starting system

-GG under speed during motoring. available?

yes
Starting system
activated?

no NGG at
ESN if not reached in 60 sec
motoring
speed? (2100
yes rpm)
yes
Starting device Motoring
deactivated (15min) yes

Any motoring
abort condition System in engine
End active?(1) lockout (4 hrs)
no
Motoring time
elapsed?
84 End
(15min)
 Start
14- Cool down sequence

Cool down
timer Ventilation Lube oil cooler
activated (240 timer activated timer activated
min) (120 min) (240 min)

High power condition Timer

no
Timer
no Timer
no

During normal operation T48 has reached expired

?
expired
?
expired
?

620 C at least once. yes yes yes

High power
condition Aux mineral
no reached?(1 Ventilation Lube oil cooler
pump
) system stop system stop
deactivated
End yes

End End
ESN? Mineral oil vapor
no
separator
deactivation
yes
no
Ventilatio
System in engine n
End
lockout (4hrs) stopped?

Motoring
End sequence Close fuel block /
open fuel vent

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THANK YOU !

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