Manual Mto 1203 - 5,6 MW

Service and Maintenance Instructions for Gas Turbine
THM N° 684
THM 1203 5,6
MAN Diesel & Turbo SE

Version: 01.2011
Table of Contents
1 General safety information.................................................................. 1
1.1 Types of references ...................................................................1
1.2 Safety information......................................................................2
1.2.1 Purpose of machine unit .............................................2
1.2.2 Intended use ...............................................................3
1.2.3 Improper use...............................................................3
1.2.4 Operating Instructions.................................................3
1.2.5 Escape routes, safety facilities....................................3
1.2.6 Attendance and operation of the plant unit .................3
1.2.7 Malfunctions, damage, service and maintenance
measures ....................................................................4
1.2.8 Work on electrical systems .........................................5
1.2.9 Access to the noise control enclosure or the
machine house ...........................................................6
1.2.10 Fire and explosion hazard...........................................6
1.2.11 Fire alarm, discharge of fire extinguishing gas............6
1.2.12 Personal protective equipment ...................................6
1.2.13 Spare parts, modifications to the scope of supply.......6
2 Introduction ........................................................................................ 1
2.1 Code word and machine no.......................................................1
2.2 Marking of component parts ......................................................1
2.3 Pressure data ............................................................................1
2.4 Service.......................................................................................1
2.5 Copyright ...................................................................................2
2.6 Conversion tables......................................................................3
3 General service and maintenance information .................................... 1

3.1 Safety information......................................................................1
3.2 Performance of service and maintenance measures.................1
3.3 Cleanliness ................................................................................1
3.4 Impact of adhesive tape.............................................................2
3.5 Consumables.............................................................................2
3.6 Examination of component parts ...............................................2
3.7 Marking of component parts ......................................................2
3.8 Storage of spare parts ...............................................................2
3.9 Performance of welding work ....................................................3
3.10 Installation of O-rings.................................................................3
Version 01-2011 General safety information

TGS_ O32410018 © MAN Diesel & Turbo SE 1|1-1
Service and Maintenance Instructions
3.11 Use of graphite pastes .............................................................. 3

3.12 General notes on the exchange of component parts ................ 4
3.12.1 Safety information ...................................................... 4
3.12.2 Exchange of pressure switches.................................. 4
3.12.3 Exchange of electric motors ....................................... 4
3.12.4 Exchange of limit switches ......................................... 5
3.12.5 Exchange of thermometers and pressure gauges...... 5
3.12.6 Exchange of swing check valves and shut-off
valves ......................................................................... 5
3.12.7 Exchange of transmitters (resistance
thermometers, pressure sensors, etc.)....................... 5
3.13 Use of SWAGELOK adapters ................................................... 6
3.14 Use of thread sealing tape and thread sealant.......................... 7
3.14.1 Thread sealing tape.................................................... 7
3.14.2 Thread sealants.......................................................... 7
3.15 Storage and installation of hoses .............................................. 7
3.16 Installation of locking plates .................................................... 10
3.17 Snap rings............................................................................... 10
3.18 Use of locking wire .................................................................. 11
3.19 Tightening torques .................................................................. 15
3.19.1 Tightening torques for pipe flanged connections...... 15
3.19.2 Tightening torques for base engine connections...... 15
3.19.3 Tightening torques for other threaded unions........... 16
3.20 Service and maintenance – Definition of terms and
objectives ................................................................................ 18
3.20.1 Inspection................................................................. 19
3.20.2 Maintenance............................................................. 19
3.20.3 Repair....................................................................... 19
4 Base frame .........................................................................................1

4.1 System-related information ....................................................... 1
4.1.1 Design and function.................................................... 1
4.1.2 Oil reservoir ................................................................ 1
5 Base engine........................................................................................1
5.1.1 Design and function of base engine ........................... 1
5.1.2 Functional principle .................................................... 1
5.1.3 Calculation of the equivalent operating hours ............ 2
5.1.5 Inspection measures V1, V2, V3, and V4................... 3
5.1.6 Maintenance............................................................... 4
General safety information Version 01-2011
1|2-2 © MAN Diesel & Turbo SE TGS_ O32410018

5.1.7 General repair information ..........................................4
5.1.8 Spare parts catalogue.................................................4
5.2 Gas generator............................................................................5
5.2.1 Design and function of gas generator .........................5
5.2.2 Modular design of gas generator ................................6
5.2.3 Modules of gas generator ...........................................8
5.2.4 Compressor ................................................................8
5.2.5 Combustion chambers ..............................................12
5.2.6 Gas collector.............................................................13
5.2.7 HP turbine.................................................................14
5.2.8 Support of the GG rotor ............................................15
5.3 Power turbine ..........................................................................19
5.3.1 LP turbine rotor / LP stator blade carrier ...................19
5.3.2 LP main casing / exhaust elbow ...............................21
5.3.3 Support of LP turbine rotor........................................22
6 Base engine instrumentation ............................................................ 23

Brief description .................................................................................23
6.1 Speed measurement (nGG, nPT)...........................................26
6.2 PT inlet temperature measurement (T4)..................................27
6.3 Vibration measurement............................................................29
6.4 Phase angle measurement......................................................30
6.5 Wear measurement on thrust bearing .....................................30
6.5.1 Safety information .....................................................31
6.5.2 Inspection .................................................................31
7 Fuel gas system ............................................................................... 32

7.1 System-related information......................................................32
7.1.1 Design and function ..................................................32
7.1.2 Fuel gas specification ...............................................32
7.1.3 Inspection .................................................................36
7.1.4 Repair .......................................................................36
7.2 Gas control valve.....................................................................37
8 Ignition system ................................................................................. 39

8.1 System-related information......................................................39
8.1.2 Safety information .....................................................40
8.1.3 Inspection .................................................................40
8.1.4 Ignition test ...............................................................40
8.1.5 Repair .......................................................................41

Service and Maintenance Instructions
8.2 Ignition electrodes ................................................................... 41

8.2.1 Design and function.................................................. 41
8.2.2 Repair....................................................................... 42
9 Blow-off and instrument air systems ...................................................1

9.1 Blow-off valves .......................................................................... 1
9.1.2 Replacement .............................................................. 2
9.2 Solenoid valves (for activation of blow-off valves)..................... 2
9.3 Pressure sensors compressor discharge pressure / PT
inlet pressure ............................................................................ 3
9.4 Pressure transducer.................................................................. 3
9.4.1 Subcontractor documentation .................................... 3
10 Cleaning system .................................................................................1

10.1.2 Time of cleaning ......................................................... 1
10.1.3 Use of cleaning additives ........................................... 2
10.1.4 Use of antifreeze ........................................................ 2
10.1.5 Cleaning sequence..................................................... 3
10.1.6 Wash water specification / approved cleaning
additives ..................................................................... 3
10.1.8 Measures to be taken before initiating the
cleaning sequence ..................................................... 5
10.1.9 Performance of cleaning ............................................ 6
10.1.10 Measures after cleaning ............................................. 6
10.1.11 Checking of cleaning result ........................................ 7
10.1.12 Repair......................................................................... 7
10.2 Cleaning nozzles....................................................................... 7

1 General safety information
This Chapter summarizes the most important safety information which
must be complied with mandatorily and at all times. For further safety
information specific to particular components and systems refer to the
respective system descriptions.
U Danger
Hazard of personal injury and damage to property!
If the general safety information is not observed there is
DANGER TO LIFE AND LIMB
as well as the risk of severe damage to property.
1.1 Types of references

The present instructions differentiate between the following types of
references:

Caution
Risk of damage to property!
A warning of this hazard classification indicates a potentially
hazardous situation which, if not avoided, may result in
damage to property.
The instructions given under this warning must be observed
to avoid physical damage to the machine unit.
U Caution
Hazard of minor injury!
hazardous situation which, if not avoided, may result in
minor injury.
to avoid personal injury.
Warning
Hazard of fatal or serious injury!
hazardous situation which, if not avoided, could result in
death or serious personal injury.
to avoid possible danger to life or serious personal injury.
U Danger
Hazard of fatal or serious injury!
A warning of this hazard classification indicates a basically
hazardous situation which, if not avoided, will inescapably
result in death or serious personal injury.
to avoid inescapable danger to life or serious personal
injury.
Notice
Notice for emphasizing information.
This notice may include information which are relevant for safe use or
may serve to emphasize important information.
1.2 Safety information
1.2.1 Purpose of machine unit

The machine unit has been designed and built exclusively for the use as
defined in Section 1.2.2 Intended use [J 1 | 3]. For any injury to persons
or damage to physical assets and property caused by improper use of the
machine unit the Operator / User of the machine unit shall be liable, not
the manufacturer.

1.2.2 Intended use
The machine unit is intended exclusively for the compression of natural
gas within the technical limits of application by utilizing the energy of the
fuel gas.
1.2.3 Improper use
U Danger
Hazard of fatal injury!
Improper use may cause design limits to be exceeded
resulting in a risk of severe damage. Damaged machine
parts may cause fatal injury.
The following is considered as improper use:
▶ Any use of the machine unit other than described in
Section 1.2.2 Intended use [J 1 | 3], without written
approval by the manufacturer.
▶ Any operation outside the technical limits of application.
1.2.4 Operating Instructions

The Operating Instructions must be supplemented by the Operator / User
with the legal regulations, provisions for the prevention of accidents,
directives and guidelines, safety data sheets, other specifications and first-
aid measures that apply to the operation of the plant in the particular
country.
It must be ensured that the persons in charge of operation and service /
maintenance have read and understood the most recent version of the
Operating Instructions.
It must be ensured that the Operating Instructions (especially the safety
information and/or the information provided therein for service and
maintenance of the plant unit) are observed and complied with at all times.
1.2.5 Escape routes, safety facilities

Before operating the plant unit, the operation and service/maintenance
personnel have to familiarize themselves with the location of the
emergency-stop buttons and/or manual actuators of the fire-fighting
system and other safety/protective facilities!
Safety facilities must not be bypassed, removed or rendered ineffective
without authorization.
Escape routes and access to the safety facilities must be kept clear at all
times.
1.2.6 Attendance and operation of the plant unit
1.2.6.1 Personnel qualification

The plant unit may be operated only by personnel who are familiar with its
mode of operation / function and who are fully skilled in operating the unit.
Above that, this personnel must know and understand the process

sequences of open- and closed-loop control, the operating parameters

(especially the standard parameters) and the limit values.
1.2.6.2 Measures before and after start-up of the plant unit

Before start-up and after run-down, the plant unit must be checked for
leakages, safe attachment of component parts and all other conditions
with an influence on safe operation of the unit. Any malfunctions and
damage must be corrected immediately.
Before starting up the plant unit, make sure that nobody is endangered,
that nobody is in the vicinity of pressure lines or inside the noise control
enclosure, and that the doors of the noise control enclosure are closed.
If the gas turbine unit is installed in a machine house without a noise
control enclosure, nobody is allowed to stay in the vicinity of the gas
turbine either. The Operator / User has to make sure that the machine
area is safeguarded against unauthorized access.
If the coupling between gas turbine and driven machine is disengaged, the
gas turbine unit must not be started up under any circumstances.
1.2.7 Malfunctions, damage, service and maintenance

measures
1.2.7.1 Elimination of malfunctions and correction of

damage
Malfunctions and damage which constitute a risk to personnel and the
plant unit must be eliminated and corrected immediately.
1.2.7.2 Personnel qualification

Service and maintenance of the plant unit may only be carried out by
personnel who are familiar with the mode of operation / function of the unit
and who are appropriately skilled for carrying out service and maintenance
measures.
1.2.7.3 Measures prior to start of service and maintenance

Before start of service and maintenance work, the following measures
shall be carried out. Operator controls and/or shut-off valves shall be
secured to prevent accidental actuation and shall be provided with a
warning sign. The individual system descriptions may include notes if this
procedure is not required for certain service and maintenance work (e.g.
filter change on a changeover-type filter).
■ The key for initiating the start-up process of the gas turbine unit shall be
removed and kept in a safe place where it is protected from
unauthorized access.
■ If a CO2 fire-fighting system is installed, this must be locked against
unintentional release for the period of performance of work inside the
noise control enclosure during standstill of the gas turbine unit. Hazard
of suffocation in case of non-observance!

control enclosure, a possibly installed CO2fire-fighting system must also
be locked against unintentional release if work is carried out in the
immediate vicinity of the machine or of detectors of the fire-fighting
system.
In the event of deactivation of the fire-fighting system, the Operator /
User shall be responsible for taking alternative fire protection measures
to the required extent.
■ All the doors of the noise control enclosure and all the respective
escape doors of the machine house must be unlocked.
■ Fuel supply to the gas turbine unit shall be shut off.
■ Depending on the actual system used, the starter system shall be
disabled either by removing the MCC starter motor plug-in module or by
shutting off fuel supply.
■ In case work has to be carried out in the environment of the fuel gas
system it shall be checked in advance by means of a suitable manual
gas detector that this environment is free from gas.
■ Before starting service and maintenance work, make sure that all
dangerous movements of machine parts have stopped, all pressurized
components have been unloaded, and hot components have
adequately cooled down.
1.2.7.4 Fire and explosion hazard

After completion of work on the fuel system, check the areas where work
has been carried out for leakages. If this instruction is not observed, there
is a risk of fire and explosion. Generally, piping should never be checked
for leakage with the hand in order to avoid serious injury as a result of high
pressure.
1.2.7.5 Work on piping

Never depressurize or drain piping by loosening a blind plug or a cap nut.
Tighten pipe unions only when the system is not pressurized.
1.2.7.6 Miscellaneous
One person should never work alone; other people should always be
nearby.
1.2.8 Work on electrical systems

Work on electrical systems of the plant unit must be carried out only by
qualified and trained skilled personnel. The relevant safety regulations for
work on electrical equipment must be observed.
Before starting on service and maintenance work, all circuit breakers have
to be opened, locked, and fitted with a warning sign.
Work on plant unit components with dangerous contact voltage (e.g.
ignition system) must be carried out with utmost care because of the very
high voltage involved. The person carrying out the work has to stand on a
rubber mat and wear appropriate special gloves and safety goggles. The
residual voltage which is present in high-voltage power circuits may still be

lethally high for a few hours after rundown and has to be routed off using a
thick-insulation cable. Before start of work, each phase has to be short-
circuited with the earthing system.
1.2.9 Access to the noise control enclosure or the machine

house
The noise control enclosure or the machine house must not be entered
during gas turbine operation! Danger to life!
Exceptions, if any, are detailed in the relevant system descriptions.
If a CO2 fire-fighting system is installed, this must be locked against
unintentional release prior to entering the noise control enclosure during
standstill of the gas turbine unit. Hazard of suffocation!
control enclosure, the Operating Instructions shall be supplemented by the
Operator / User with appropriate safety precautions in connection with a
fire-fighting system.
1.2.10 Fire and explosion hazard

Smoking, open flames and other sources of ignition in the vicinity of the
plant unit are strictly forbidden.
If, nevertheless, welding or cutting should be carried out in the
environment of the plant unit, appropriate precautions have to be taken
(e.g. provision of firemen).
Any repair of explosion-proof component parts may be carried out only by
the manufacturer; otherwise, acceptance by a certified authorized
inspector is required.
1.2.11 Fire alarm, discharge of fire extinguishing gas

In the event of a fire alarm, leave the noise control enclosure and/or the
machine house at once and shut the doors.
If a CO2 fire-fighting system is installed and extinguishing medium has
been discharged, compartments filled with CO2 may only be entered again
following thorough ventilation. Hazard of suffocation!
1.2.12 Personal protective equipment

Protective clothes (safety helmet, safety goggles, ear protectors, gloves,
etc.) must always be worn considering the respective requirements.
When handling operating media, consumables, and other hazardous
substances (e.g. solvents, cleaning agents, acids, etc.) the applicable
manufacturers' safety data sheets shall be observed. When working with
such substances, do not breathe the vapours that may develop.
1.2.13 Spare parts, modifications to the scope of supply

Only original spare parts supplied and approved by MAN DIESEL &
TURBO SEwithin the scope of supply of MAN DIESEL & TURBO SEmay
be installed.

Any changes (modifications, retrofits, attachments, etc.) to the scope of
supply of MAN DIESEL & TURBO SE may be carried out only by MAN
DIESEL & TURBO SE or after consultation with MAN DIESEL & TURBO
SE. Non-observance will render any warranty claims null and void and
may result in safety deficiencies, operational malfunctions, and personal
injury and damage to property.

2 Introduction
2.1 Code word and machine no.
The unit(s) supplied is/are identified by the code word assigned by MAN
DIESEL & TURBO SE
A name plate with the following information is attached to the gas
generator and to the power turbine:
■ Machine type
■ Machine serial no.
■ Year built
■ Contractually assured unit output as per ISO conditions
■ Direction of rotation (With THM units, the direction of rotation seen in
the direction of flow is always clockwise.)
The name plate of the gas generator is attached on the left at the upper
main casing half of the gas generator, seen in the direction of flow. The
name plate of the power turbine is attached to the outlet flange of the
power turbine casing in 9 o’clock position, also seen in the direction of
flow.
In communication with MAN DIESEL & TURBO SE the unit code word
and/or in case of machine-related matters the corresponding machine
serial no. shall always be indicated.
2.2 Marking of component parts

The functionally relevant plant unit components and I&C parts are locally
marked with so-called TAG codes. These allow identification of the
component part and allocation to the individual systems.
The TAG code is composed of letters and digits.
The "P&I Diagram" includes explanations on the different letter codes and
on the symbols used in the P&I Diagrams.
2.3 Pressure data

Unless stated otherwise, all pressure data in the Operating Instructions
shall be understood as gauge pressure above atmospheric pressure ( bar
g ).
For information about the pressure data of the driven machine, see the
relevant documentation.
2.4 Service
Compliance with the procedure described in the following ensures speedy
processing of your enquiry / order.
Please direct general questions and queries as regards spare parts,
personnel, fault analysis / troubleshooting, repair, engineering,
modifications, etc. to the competent contact for the plant unit with the MAN
DIESEL & TURBO SE After Sales Service.
Version 01-2011 Introduction

For spare parts enquiries and orders, quote the material no. and
designation as well as the required quantity. If a material no. is not
available, either indicate the TAG code or describe the component part as
precisely as possible.
Shipment of component parts to the MAN DIESEL & TURBO SE works
shall be made with consideration to the materials receiving times
mentioned in the following and with indication of the code word or the
machine number. Prior to shipment the competent contact for the plant
unit should be informed and this person should also be named additionally
as consignee.
Materials receiving Monday to Friday from 06.00 to 13.00 hours

times
Shipping address MAN Diesel & Turbo SE
Incoming Materials
Department / Name of competent contact for the plant unit
Steinbrinkstrasse 1 (Tor 6)
46145 Oberhausen
2.5 Copyright
The Operating Instructions supplied by MAN DIESEL & TURBO SE may
only be used for the purpose specified by MAN DIESEL & TURBO SE.
MAN DIESEL & TURBO SE reserve all property rights in the Operating
Instructions. The Operating Instructions may not be copied, modified, or
made available to third parties, in whole or in part, except as permitted by
the statutory regulations and with prior written approval by MAN DIESEL &
TURBO SE; they may be copied, without our specific approval, for the
purpose of operation and service/maintenance of the delivered plant unit
on customer's premises.
Introduction Version 01-2011

2.6 Conversion tables
Physical quantities in the present Operating Instructions are mostly indicated
according to the international unitary system (Système International d’Unités / SI). If
in the country where the plant unit will be installed the SI system is not applied, the
quantities indicated in the Operating Instructions can be converted by means of the
following tables.
Conversion of temperature
T °C °F °R °K
°C 1 9 : 5 °C + 32 9 : 5 · °C – 491,69 °C + 273,15
°F (°F - 32) · 5 : 9 1 °F + 459,69 (°F-32)·5:9+273,15
°R (°R – 491,69)·5 : 9 °R – 459,69 1 9 : 5 · °R
°K °K – 273,15 32+9:5·(°K–273,15) 9 : 5 · °K 1
Conversion of pressure
p Unit kPa Pa mbar mmWG inch H2O psia

1 kPa = 1 1000 10 101,972 4,0146 0,14504
1 Pa = 0,001 1 0,01 0,10197 0,0040146 0,0001450
4
1 mbar = 0,1 100 1 10,197 0,40146 0,014504
1 mmWG = 0,009807 9,8067 0,098067 1 0,039370 0,0014223
1 inch H2O = 0,249089 249,089 2,49089 25,400 1 0,036127
1 psia = 6,8948 6894,8 68,948 703,074 27,680 1
760 mmHg = 101.325 kPa = 14.696 psia = 29.92 Hg
Conversion of linear measure
L Unit mm m inch feet yard

1 mm = 1 0,0010 0,0393701 0,0032808 0,0010936
1 m= 1000 1 39,3701 3,2808 1,0936
1 inch = 25,40 0,0254 1 0,083333 0,027778
1 ft = 304,8 0,3048 12 1 0,3333
1 yd = 914,4 0,9144 36 3 1

Conversion of square measure
A Unit m2 square inch square feet

1 m= 1 1550,0031 10,7643
1 sq. in. = 0,00064516 1 0,0069444
1 sq. ft. = 0,09229 144 1
Conversion of capacity measure
V Unit m³ cubic feet gallon

1 m³ = 1 0,028317 264,17
1 cu. ft. = 35,31 1 7,4817
1 gallon = 0,0037854 0,13366 1
Conversion of mass
m Unit kg ounce pound slug

1 kg = 1 35,2734 2,2046 0,068522
1 ounce = 0,02835 1 0,0625 0,0019426
1 lb = 0,4536 16,0000 1 0,031081
1 slug = 14,5939 514,78 32,174 1
Conversion of energy
E Unit kJ Btu kcal

1 kJ = 1 0,94782 0,23885
1 Btu = 1,05506 1 0,25205
1 kcal = 4,1868 3,9675 1
Conversion of specific energy
e Unit kJ/kg Btu/lb

1 kJ/kg = 1 0,4299
1 Btu/lb = 2,3260 1
Introduction Version 01-2011

Conversion of specific heat
cp Unit kJ/(Kg K) Btu/(b °F)

1 kJ/(kg K) = 1 0,23885
1 Btu/(lb°F)= 4,1868 1
1 Btu/(lb °F) = 1 kcal/(kg °C)
Conversion of power
P Unit kW hp
1 kW = 1 1,3410
1 hp = 0,7457 1

3 General service and maintenance information
3.1 Safety information
U Danger
Danger to life and limb as well as risk of severe damage to
property!
Prior to performance of a service and maintenance measure
Chapter 1 General safety information [J 1 | 1] and the
safety information included in the system and component
part descriptions shall be observed.
Caution
Damage to components of the gas turbine unit!
The general service and maintenance notes listed below
have to be observed to avoid damage to the gas turbine
unit.
3.2 Performance of service and maintenance measures

Gas generator, power turbine and coupling may only be replaced or
aligned under instruction by a representative of MAN DIESEL & TURBO
SE, since special knowledge is required for the performance of these
measures. This also applies to the performance of repair work on internal
base engine parts.
Service and maintenance work which is not described in the
documentation supplied may only be carried out by persons with special
qualification and skills to whom adequate information is available. Lacking
information may be requested from the competent contact for the plant
unit with the After Sales Service of MAN DIESEL & TURBO SE.
3.3 Cleanliness
Care has to be taken to ensure that dust, dirt, locking elements or other
foreign objects do not get into the gas turbine. Should this ever happen,
the service and maintenance activity must be suspended until the
respective objects have been found, even if this requires a considerable
input of cost and time.
Suitable plugs, caps or other covers are to be used for the protection of all
non-covered openings. Protective caps for open pipes shall not be placed
inside but on top of the pipe ends in order to prevent their being installed
unintentionally. Use of adhesive tape is not permitted (see Section 3.4
Impact of adhesive tape [J 3 | 2] ).
Anti-corrosion agents, applied for the storage of component parts, as well
as dirt and packaging material shall be carefully removed prior to
Version 01-2011 General service and maintenance information

installation of a part. Suitable solvents shall be used for the removal of

anti-corrosion agents.
After completion of service and maintenance work, especially the intake
area is to be thoroughly checked for foreign objects which might, for
example, get into the gas path of the base engine.
3.4 Impact of adhesive tape

Investigations have shown that with increasing temperature remainders of
adhesive tape on component parts attack the surface and reduce the
expansion capability. Remainders of adhesive tape are to be removed
carefully, before a component part is installed and exposed to high
temperatures.
3.5 Consumables
During each assembly operation all seals and rubber parts are to be
replaced. Prior to installation, non-metallic new parts have to be checked
for indications of damage resulting from extended periods of storage.
Consumables, such as for example locking wire, locking washers, locking
plates, split pins, etc., must not be reused.
3.6 Examination of component parts

Prior to installation of a component part it has to be checked whether the
part to be installed is correct and undamaged. Use of incorrect or
damaged component parts or of other than original parts not procured
from MAN DIESEL & TURBO SE may result in failure or major damage to
the plant unit.
During disassembly of component parts watch out for indications of wear,
burns or other undesirable changes.
3.7 Marking of component parts

During disassembly note the installation location of each individual part for
ease of reinstallation. Mark the parts, if necessary, taking the following
notes into account.
Damaged component parts or subassemblies which cannot be reused are
to be marked with a tag in order to avoid unintentional installation.
The internal parts of gas generator and/or power turbine shall only be
marked using special pens. We recommend using the glass chromium pen
by Messrs Stade or a silver pen by Messrs Faber for the marking of
component parts.
3.8 Storage of spare parts

As a rule, spare parts procured from MAN DIESEL & TURBO SE are
packaged and preserved for storage according to requirements.
Spare parts shall be stored in a room at constant temperature between 15
and 25 °C. The relative humidity must not exceed 70%. Temperature
variations are to be limited to max. 1 °C per hour.
General service and maintenance information Version 01-2011

Anti-friction bearings are delivered in the manufacturer's original
packaging. As a rule, the maximum storage period is 2 years. After this,
exchange the parts if preservation proves too expensive.
Component parts from rubber-like materials, e.g. shaft sealing rings, O-
rings, flexible nozzles, vibration dampers, V-belts, etc. have to be
protected from light and seal-welded into black film. Check these parts
annually for elasticity and brittleness. The maximum storage period is 5
years or less, depending on the instructions by the respective
manufacturer. For this reason, these parts are to be marked with the date
of storage to permit checking.
Stored component parts with metallic surfaces are to be checked annually.
The preservation of machined surfaces has to be touched up, if
necessary. Bright, metallic surfaces are to be greased.
Stored component parts shall be identified with the material number of
MAN DIESEL & TURBO SE and recorded in an inventory list.
3.9 Performance of welding work

If welding work is carried out in the area of the GT base frame, proper
earthing must be ensured in order to avoid damage to the electrical
components installed on the base frame. Additionally, appropriate fire
prevention measures are to be taken.
3.10 Installation of O-rings

For ease of installation, O-rings which come into contact with oil are to be
coated with the oil of the system in which the O-ring is used.
O-rings which come into contact with water may be coated with Vaseline
for ease of installation.
3.11 Use of graphite pastes

To facilitate future removal of screwed joints in hot areas, graphite paste
Never-Seez (Material No. S0913821) shall be applied to the thread faces.

3.12 General notes on the exchange of component parts
3.12.1 Safety information
U Caution
Prior to the dismounting of component parts the following
references in Chapter 1 General safety information [J 1 | 1]
shall be observed:
▶ 1.2.7 Malfunctions, damage, service and maintenance
measures [J 1 | 4]
▶ 1.2.8 Work on electrical systems [J 1 | 5]
▶ 1.2.9 Access to the noise control enclosure or the
machine house [J 1 | 6]
▶ 1.2.12 Personal protective equipment [J 1 | 6]
▶ 1.2.13 Spare parts, modifications to the scope of supply
[J 1 | 6]
3.12.2 Exchange of pressure switches

Z Observe Section 3.12.1 Safety information [J 3 | 4].
1. Shut down the plant unit and lock it to prevent restarting.
2. Isolate the measuring line, and depressurize.
3. De-energize the measuring circuit to exclude any risk of a short circuit
which may result in damage to digital/analog cards.
4. Exchange the pressure switch.
5. Use a calibration device to check the measuring range and the switch
point. Adjust the switch point, if necessary (for values see).
3.12.3 Exchange of electric motors

In the case of motors which are new, which have been cleaned or repaired
and in the case of motors which have been in store or shut down for 6
months, determine the minimum insulation resistance of the motor
winding. After an extended period of operation also check the critical
insulation resistance.
During and immediately after the measurement the terminals sometimes
have dangerous voltages and must not be touched.
If the minimum insulation resistance or critical insulation resistance has
decreased below the specified value, the motor must not be started up or
has to be shut down at once.
Possible causes for this could be, for example, humidity, damaged
windings or winding parts.
2. Safely isolate the motor.

3. Lock the motor to prevent restarting.
4. Verify safe isolation from supply.
5. Ground and short-circuit the motor.
6. Cover or barrier off adjacent, live parts.
7. Reverse the above measures only after the motor has been completely
reinstalled and connected again.
3.12.4 Exchange of limit switches

3. Exchange the limit switch.
Note: If the limit switch is designed as initiator, make sure that the
polarity is correct.
3.12.5 Exchange of thermometers and pressure gauges

2. Isolate the piping, and depressurize.
3. Exchange the thermometer or pressure gauge.
3.12.6 Exchange of swing check valves and shut-off valves

2. Isolate the piping, and depressurize.
3. Exchange the swing check valve or shut-off valves. Use new gaskets
and observe the direction of flow.
3.12.7 Exchange of transmitters (resistance thermometers,

pressure sensors, etc.)
3. Exchange the transmitter.
Note: If the transmitter is designed as initiator, make sure that the
polarity is correct.
4. For exchanging a resistance thermometer in case an immersion sleeve
is not installed: Isolate the piping, and depressurize.

5. Use a calibration device to check the setting or programming and

function, and pass through the entire measuring range for checking the
linearity (values see).
3.13 Use of SWAGELOK adapters

In the gas turbine area SWAGELOK® adapters are used with a maximum
diameter of 25 mm since pre-assembly tools are not necessary up to this
size. SWAGELOK® adapters can be loosened and re-tightened several
times without any of the parts shown in the Figure below having to be
exchanged.
SWAGELOK adapter
1 Cap nut 3 Front clamping ring

2 Rear clamping ring 4 Body
Z If an adapter has to be exchanged or installed all the same, take care to

ensure that the pipe end is rectangular and free from burs. Remnants
from burs and other contaminations must not get into the piping. The
following procedure has to be observed:
1. Insert the pipe into the assembled SWAGELOK® adapter. Make sure
that the pipe has been introduced into the adapter up to the stop and
the cap nut tightened "finger-tight".
2. Prior to tightening the cap nut mark it in 6 o'clock position.
3. While holding the body with a wrench, tighten the cap nut by 1-1/4
turns. Note that after one complete turn the marking has to be turned
further up to 9 o'clock position.
Notice
Use of sealants
Sealants may not be applied to SWAGELOK® adapters.
On the SWAGELOK® adapters the measurement of tightening torques is

not suitable for checking the tightening. Merely the 1-1/4 turn of the cap
nut is the correct measure for adequate tightening. If the reference gauge

fits between the cap nut and the body hexagon, the adapter has not been
tightened sufficiently. If it does not fit, the adapter has been tightened
sufficiently.
3.14 Use of thread sealing tape and thread sealant
3.14.1 Thread sealing tape
Notice
Use of thread sealing tape
Thread sealing tape may only be used for tapered male threads. Use
for connections with flanges, cones or pipe unions is not allowed.
Z For tapered male threads with a diameter of 1/8", 1/4" and 3/8" a thread
sealing tape with a width of 1/4" is to be used. For a larger thread a tape
of 1/2" width is to be used. The following procedure has to be observed:
1. Clean the male and female threads in order to remove any anti-seize
compound or sealing residues.
2. Starting on the first flight, wind the sealing tape with slight overlap
around the thread in threading direction. For tapered threads from
special steel, winding the tape twice around the thread is
recommended.
3. Make sure that the tape does not protrude beyond the first turn of the
thread, since otherwise it might break and get into the component part.
4. Protruding sealing tape has to be cut off. The tape, especially the
overlapping ends, shall be pressed against the thread.
3.14.2 Thread sealants
Notice
Use of thread sealants
Thread sealants may only be used for tapered male threads. Use for
cable glands is not permitted.
Prior to the application of thread sealant the whole thread has to be

cleaned from oil, grease and other impurities. The thread sealant is to be
applied to the second and third flights.
3.15 Storage and installation of hoses
Notice
Open hose ends
Open ends of stored hoses have to be capped or plugged in order to
prevent any accumulation of dirt in the hose interior.
Z The service life of a hose largely depends on the correct installation.

The following has to be observed for the installation of hoses:

1. Hoses shall be reeled and unreeled as shown in the following Figure

"Reeling and unreeling of hoses".
2. Check prior to installation that the hose interior is free from dirt. As a
precautionary measure blow the hose through with compressed air prior
to installation.
3. As a rule, the hoses are equipped with one loose and one fixed hose
connection fitting. The fixed hose connection fitting always has to be
tightened first to prevent torsional stress.
4. Always use a wrench as dolly to avoid co-rotation of the connection
mating piece or damage to the piping to be connected.
5. External straining of the hose by chafing on edges, surfaces or on the
ground has to be avoided, as the service life may be reduced
considerably by bending or by reduction of the wall thickness.
6. During installation care must be taken that the minimum bending radius
specified in the table below is maintained.

7. Attachment of a hose in the way such as illustrated in "Inadmissible
attachment of hose" is not permitted.
Reeling and unreeling of hoses
Hose minimum bending radius
Inadmissible attachment of hose
Minimum bending radius for corrugated hoses of special steel
Nominal diameter (inch) Bend minimum radius (mm)

3/8 200
1/2 220
5/8 300
3/4 330
1 390
1-1/4 410
1-1/2 490
2 570
2-1/2 680
3 770

Nominal diameter (inch) Bend minimum radius (mm)

4 960
3.16 Installation of locking plates
Notice
Reuse of locking plates
Locking plates must be used only once.
When using locking plates care has to be taken to ensure that the gap
between the bent-over tabs and the contact face is max. 0.50 mm. At least
75% of the securing tab must be in contact with the face of the component
part.
Installation of locking plates
3.17 Snap rings

Suitable pliers are to be used for the installation of snap rings. Internal
snap rings must not be pressed together beyond the point where the ends
of the rings meet. External snap rings must only be expanded to such an
extent that installation is possible without bending the rings. After
installation it has to be ensured that the snap ring rests firmly in the groove
and is neither loose nor deformed. Deformed snap rings have to be
replaced.
Chamfered snap rings additionally serve for absorbing the tolerance
clearance of the component part to be retained. Such snap rings have a
chamfer of 15° on one side. Chamfered snap rings may only be inserted in
correspondingly chamfered grooves. The non-chamfered side must face
the component part to be retained.
3 | 10 - 10 © MAN Diesel & Turbo SE TGS_ O32410018

3.18 Use of locking wire
Notice
Use of locking wire
The use of locking wire which has been in use before, which is bent or
damaged is not admissible.
No other than the locking wire supplied by MAN DIESEL & TURBO SE
shall be used. The bores for the locking wire shall be aligned as shown in
the following Figures. During alignment the specified tightening torques
must not be exceeded. Subsequently, the locking wire is to be fitted as
shown. The end of the locking wire has to be bent over to avoid any
hazard of injury.
In THM gas turbine units locking wires with a diameter of 0.8 mm (material
no. S0293782) and 1.25 mm (material no. S0293781) are used.
In FT8 gas turbine units locking wire of material no. TAS3214-02 is mainly
used.

TGS_ O32410018 © MAN Diesel & Turbo SE 3 | 11 - 11
Examples for the securing of component parts with locking wire



3.19 Tightening torques
U Caution
Hazard of personal injury and damage to machinery!
If tightening torques are not observed, component parts may
work loose and - especially where rotating component parts
are concerned - may hit people in the vicinity of the plant
unit. Above that, hot and pressurized liquids or gases may
escape from pipes and casings and likewise hit people in
the vicinity of the plant unit.
Notice
Prerequisites for the tightening of threaded unions.
Component parts shall only be tightened to the final torque after room
temperature has been reached.
Flanged connections are to be tightened crosswise alternately with

approx. 75% of the tightening torque, before the final tightening torque is
reached. Torque wrenches are to be calibrated regularly.
For information about the tightening torques for the driven machine and
other plant unit components please refer to the relevant documentation.
3.19.1 Tightening torques for pipe flanged connections

In most cases, threaded bolts with UNC thread are used for the
connection of pipe flanges. Flanged connections are to be tightened
alternately and crosswise by applying the following tightening torques. The
data apply for non-greased threaded bolts which are stamped with "B7" on
the front face. Where the stamping is different, other tightening torques
apply.
Tightening torques for stud bolts with UNC thread
Dimensions (inch) Tightening torque (Nm)

1/2 95
5/8 199
3/4 347
7/8 554
3.19.2 Tightening torques for base engine connections

The following table lists the standard tightening torques for the base
engine. Do not apply these tightening torques unless in the description of
service and maintenance measures express reference is made to the
tightening torques in this table. In all other cases special tightening torques
apply which must be observed by all means.

Tightening torques for base engine connections
Bolt / nut diameter Minimum (Nm) Maximum (Nm)

M5 2,6 3
M6 4,8 6
M8 11 15
M 10 23 28
M 12 39 45
M 14 63 80
M 16 96 130
M 18 130 180
M 20 187 250
M 22 250 320
M 24 320 450
M 27 469 580
M 30 588 750
Unless indicated otherwise, thread faces are to be greased.
3.19.3 Tightening torques for other threaded unions
Notice
Tightening torques for other threaded unions
The tightening torques listed in the table below are not valid for the
base engine and for flanged pipe connections.
The standard tightening torques for other connections are indicated in the
following table. Do not apply these tightening torques unless in the
description of service and maintenance measures express reference is
made to the tightening torques in the table below. In all other cases
special tightening torques apply which must be observed by all means.
Tightening torques for other connections (part 1 of 2)
Bolt / nut diameter Bolt strength Tightening torque Tightening torque

category/ Ma (Nm) Ma (Nm)
Material MoS2 - lubr. lightly oiled
M8 5.6 10 11
8.8 21 19
10.9 30 34
A2-70 12 13

Bolt / nut diameter Bolt strength Tightening torque Tightening torque
category/ Ma (Nm) Ma (Nm)
A4-80 17 19
1.7258 15 17
M10 5.6 20 23
8.8 43 48
10.9 so 68
A2-70 23 26
A4-80 33 38
1.7258 29 33
M12 5.6 33 40
8.8 71 85
10.9 100 120
A2-70 39 47
A4-80 56 67
1.7258 49 59
M16 5.6 83 117
8.8 178 248
10.9 250 350
A2-70 97 136
A4-80 139 194
1.7258 122 171
M20 5.6 150 200
8.8 320 426
10.9 450 600
A2-70 175 233
A4-80 250 333
1.7258 220 293
Tightening torques for other connections (part 2 of 2)
Bolt / nut diameter Bolt Tightening torque Tightening torque

strength category/ Ma (Nm) Ma (Nm)
M24 5.6 267 367
8.8 569 782
10.9 800 1.100
A2-70 311 428

Bolt / nut diameter Bolt Tightening torque Tightening torque

strength category/ Ma (Nm) Ma (Nm)
A4-80 444 611
1.7258 391 537
M27 5.6 417 550
8.8 889 1.173
10.9 1250 1.650
A2-70 486 641
A4-80 694 917
1.7258 611 807
M30 5.6 550 733
8.8 1.173 1.564
10.9 1.650 2.200
A2-70 642 856
A4-80 917 1.222
1.7258 807 1.076
M36 5.6 933 1.267
8.8 1.991 2.702
10.9 2.800 3.800
A2-70 1.089 1.478
A4-80 1.556 2.111
1.7258 1.368 1.858
3.20 Service and maintenance – Definition of terms and

objectives
Service and maintenance is aimed at maintaining or restoring the desired
condition of the plant unit. Service and maintenance which is carried out
regularly and carefully has a positive effect on the reliability of the plant
unit and contributes to reduction of the operating costs.
The following measures are covered by the term service and
maintenance:
■ Maintenance measures (cleaning, readjustment) for maintaining the
desired condition;
■ Inspection measures (measurement, check, diagnosis) for assessment
of the actual condition;
■ Repair measures (replacement, rework) for restoring the specified
condition.

3.20.1 Inspection
3.20.1.1 Routine inspections / walk-around checks

The overall process plant has to be inspected daily for external damage,
leakages and safe attachment. If continuous operation of the plant unit
does not allow inspection of the components installed inside the noise
control enclosure they have to be inspected after every run-down.
3.20.1.2 Oil analyses

The oil analyses which are to be carried out regularly are aimed at
permitting statements about the degree of fouling, ageing or the additive
values, and at protecting the plant unit against inadequate cooling of the
bearings due to excessive viscosity, detrimental deposits and corrosion in
the areas of the lube-oil system of gas generator and power turbine. For
information about the applicable requirements please refer to the lube oil
specification.
3.20.1.3 Checking of major functional component parts and protective equipment

We recommend having functional checks carried out together with the
service and maintenance measures V1, V2, V3, and V4 (in particular on
protective equipment) as well as calibration of major functional component
parts and assessment of the overall condition of the plant unit, including
determination of necessary repair work. If necessary, follow-up
examinations will be carried out on components which have proved
unsatisfactory during previous inspections.
3.20.2 Maintenance
Major maintenance measures include regular filling of the lube oil
reservoir, cleaning of the gas generator compressor and relubrication of
motors. The information in the respective system or component part
description has to be observed before maintenance work is started.
3.20.3 Repair
Repair of component parts or subassemblies is mainly carried out
depending on the respective actual condition, which means that fixed
dates and/or regular intervals for repair measures are not specified.
Relevant information provided by MAN DIESEL & TURBO SE shall only
be regarded as reference values for planning purposes. Point in time and
scope of necessary repairs depend on the operating conditions and on the
state and/or operating behaviour of the plant unit.

4 Base frame
4.1 System-related information
4.1.1 Design and function

The base frame of the gas turbine is a sectional-steel structure with
supports and struts to accommodate the vertical, horizontal, and axial
forces as well as torsional moments and thermal expansion of the gas
turbine. Component parts of the lube oil, starter, and fuel systems are
mounted on the base frame.
4.1.2 Oil reservoir

In its interior the reservoir of the lube-oil system, which is integrated in the
base frame, has perforated and baffle plates. The perforated plates in the
area of the lube-oil return line serve for separation of the air entrained in
the oil. The baffle plates increase the residence time of the returned oil
and ensure that the complete oil volume is utilized for lubrication.
The reservoir is equipped with
■ Manholes for inspection and cleaning,
■ Nozzles for reservoir filling, temperature and pressure measurement, as
well as inspection of filling level,
■ Ports for draining the oil and taking oil samples, and
■ Ports for accommodation of the electrically driven pumps.
Ports on base frame relevant for service
1 Ports for the electric lube-oil pumps* 3 Manholes for inspection of the oil
reservoir
2 Oil filling nozzle / Check of filling 4 Oil drain
level
Version 01-2011 Base frame

* The Figure shows a base frame for plant units with mechanically driven main
lube oil pump. If the main lube oil pump is operated electrically, there are three
pump ports in the base frame.
4.1.2.1 Support of base engine

The base engine with the inlet and exhaust elbows is held by four support
pedestals which are welded to the base frame. The two lateral power
turbine supports, the bottom mount pin plate and the two bottom mount pin
plates which are bolted to the power turbine laterally and at the bottom
form the fixed point of the gas turbine. This means that the gas turbine
expands in direction of the gas generator by thermal influence.
The floating point is formed by the two GG support pedestals and the two
brackets integrally cast with the GG main casing. In the bottom part of the
GG main casing there is also a rail for lateral guidance of the gas
generator.
The backing roll on the GG main casing is only moved down in the course
of the hot gas path inspection so that the gas generator and the power
turbine can be shifted apart.
Caution
Risk of damage to gas generator and/or base frame!
The guide roller must not contact the base frame while the
gas turbine is in operation. If this is not observed, damage
may be caused to gas generator or base frame.
In order to achieve alignment of the gas turbine with optimum precision,

shims and set bolts are provided in the area of the four pedestals.
By means of the set bolts the gas generator and the power turbine can be
shifted apart in the course of a hot gas path inspection.
Caution
Risk of damage to the base frame!
A change of the alignment by means of the set bolts or by
exchange of the shims may only be carried out by
authorized and trained personnel.
The set bolts on the GG pedestals must not be in contact
with the brackets of the GG casing. It has to be ensured that
a distance of 20 mm is maintained.
Base frame Version 01-2011

Base frame*
1 Support pedestal GG 4 Support pedestal PT

2 Guide rail GG 5 Bottom mount pin plate PT
3 Backing roll GG
* The Figure above shows a THM gas turbine with standard combustion
chambers. The base frame of THM gas turbines with DLN combustion
chambers is of identical design; in view of their size, the DLN combustion
chambers are, however, provided with additional support.
Version 01-2011 Base frame

Detail GG support pedestal
1 Set bolts 2 Shim
Detail support pedestal PT
1 Set bolts 2 Shim
Base frame Version 01-2011

5 Base engine
5.1.1 Design and function of base engine

The core components of gas turbine THM 1203 are the gas generator and
the power turbine (also called LP turbine). They are collectively referred to
as base engine and are mounted on a base frame
5.1.2 Functional principle

The THM is a twin-shaft gas turbine operating according to the conventional simple principle of
combustion at constant pressure.
This principle (see Figure5-1) comprises the following steps:
• Adiabatic compression of air in an axial-centrifugal compressor.
• Combustion of a mixture at constant pressure in two combustion chambers. The mixture

consists of the air discharged from the compressor and the fuel (liquid fuel or fuel gas)
which is routed to the combustion chambers via nozzles.
• First expansion of the pressurized hot gases coming from the combustion chambers is
made in a two-stage backpressure turbine that is called high-pressure turbine (HP
turbine) serving to drive the axial-centrifugal compressor.
• Second expansion of the hot gases leaving the HP turbine is made in a second
backpressure turbine called low-pressure turbine (LP turbine). This turbine supplies the
energy required for driving a processing machine (e.g. pipeline compressor or electric
generator) via a shaft that is not connected to the HP turbine of the gas generator.
Version 01- 2011 Base engine

1 3 4 5
Pressure profile Temperature profile
1 GG compressor 2 Combustion chamber 3 HPturbine

4 LP turbine 5 Processing machine
Figure5-1: Pressure and temperature profile in the gas turbine
5.1.3 Calculation of the equivalent operating hours

Calculation of the equivalent operating hours (EOH) in the course of
determination of service and maintenance intervals or service lives is
necessary for the consideration of factors which have a major influence on
the condition of the base engine parts. Calculation is based on the
following formula:
EOH = operating hours ∙ A 1 ∙ A 2 ∙ A 3 + 10 ∙ number of starts
Factors for calculation of the equivalent operating hours
Factor Operating conditions Value

A1 Weighting factor for load stage
Base load (operation with nGG or T4 limitation) 1,0
Operation predominantly below 80% base load 0,9
Base load operation with recurring, short-term overload 2,0
above the T4 limitation for base load
Base engine Version 01-2011

Factor Operating conditions Value
A2 Weighting factor for fuel
Low-sulphur fuel gas 1,0
High-sulphur fuel gas 1,3
Fuel oil EL, Diesel 1,3
Other fuels on request
A3 Weighting factor for intake air
Low-pollutant intake air 1,0
Corrosive intake air, e.g. off-shore operation 1,3
Warning
Work on base engine components may only be carried out
during standstill and after a cool-down period of several
hours. Prior to the performance of service and maintenance
measures the following Sections in Chapter 1 General
safety information [J 1 | 1] shall be observed:
measures [J 1 | 4]
[J 1 | 6]
5.1.5 Inspection measures V1, V2, V3, and V4

Inspection measures V1, V2, V3, and V4 are aimed at assessing the
condition of the internal base engine component parts.
The following tables provide an overview of the times for performance of
these measures and of the scope of component parts to be inspected.
At the time of inspection of the base engine, the component parts and
protective equipment which are relevant for proper functioning can be
checked.
Inspection times for base engine
Equival. OH* 10 20 30 40 50 60 70 80 90 ...

Action V1 V2 V2 V3 V1 V2 V2 V4 V1 ...
* OH = Operating Hours. The values are to be multiplied by 1,000.

Scope of base engine component parts to be inspected
Inspection measure
V1 V2 V3 V4
Flame tubes Compressor
Gas collector Combustion chambers
HP1/HP2 stator blades Gas collector
HP1/HP2 rotor blades HP turbine
LP1 stator blades LP turbine
Flame tubes Compressor
Checking of major functional component parts and protective

equipment [J 3 | 19]
5.1.6 Maintenance
Maintenance work (cleaning, readjustment) on the base engine is limited
to keeping the outer area and the surroundings of the base engine clean
and to condition-dependent cleaning of the compressor.
5.1.7 General repair information

Repair of the components of the base engine depends on the respective
condition, which means that fixed dates and/or regular intervals for repair
measures are not specified. Relevant information provided by MAN
DIESEL & TURBO SE shall only be regarded as reference values for
planning purposes. Point in time and scope of necessary repairs depend
on the operating conditions and on the state and/or operating behaviour of
the plant unit. Assessment of the actual condition is made by the time-
dependent repair measures V1, V2, V3 and V4 as well as based on the
evaluation of operating data.
5.1.8 Spare parts catalogue

Data of spare parts for the base engine are listed in an electronic spare
parts catalogue which will be found on the electronic documentation data
carrier included in the supply. This catalogue which is structured according
to subassemblies covers all component parts of the base engine which are
indicated in parts lists and explosion drawings. A search function is
available for finding parts e.g. by means of the part no. or part designation.
Above that, a facility is provided for generating spare parts enquiries or
purchase orders. On request, the EPOS© Electronic Parts Ordering
System can be set up, which makes it possible to query e.g. spare parts
prices, delivery times, and inventories via the Internet. Furthermore,
enquiries or purchase orders for spare parts can be submitted to MAN
DIESEL & TURBO SE via the Internet.

5.2 Gas generator
5.2.1 Design and function of gas generator
Figure 1-2 illustrates the modular design of the gas generator of a THM 1203
gas turbine unit with standard combustion chambers. The modular design of a
THM permits the exchange of all modules inside the noise control enclosure
with only few equipment needed. The compressor, the combustion chamber
section, and the HP turbine are the main components of the gas generator and
are shown along with other components in the following Figure.
The gas generator generates the energy required for driving the power turbine
(see section 5.3).
Having flown through the compressor, the air drawn in gets into the
combustion chambers in V-arrangement where it is mixed up and burnt with
the fuel and in units with water injection with water. Via a gas collector the hot
exhaust gases reach the two-stage HP turbine which drives the compressor of
the gas generator. The excess exhaust gas energy is passed on to the power
turbine (LP turbine). Part of the air from the compressor is also used for
cooling the combustion chambers and turbines.

Ignition is made by two igniters operating independently from each other.

Subsequently, combustion is self-sustaining.
Fuel supply to the gas generator is made via a control valve with regard to the
required power input.
Figure 5-2: Overview gas turbine
5.2.2 Modular design of gas generator

The following Figure shows the modular structure of the gas generator for
a THM 1203 gas turbine unit with standard combustion chambers. The
modular design of a THM permits the exchange of all modules inside the
noise control enclosure with only few equipment needed.

Modular design of gas generator (shown without combustion chambers)
1 HP1 stator blade carrier 8 GG front bearing

2 HP turbine rotor 9 Compressor inlet casing
3 HP2 turbine ring 10 Upper half compressor stator blade
carrier
4 Upper half GG main casing 11 Upper half GG rear bearing
5 Gas collector 12 Compressor rotor
6 Planetary gear unit* 13 Lower half GG main casing
7 Planetary gear unit connecting
shaft*
* These parts are only installed in plant units where the starter system is equipped
with an auxiliary gear unit.
Fehler! Verweisquelle konnte nicht gefunden werden. [J 5 | Fehler!

Textmarke nicht definiert.]





5.2.3 Modules of gas generator
5.2.4 Compressor
The compressor of the THM 1203 supplying the air required for combustion and/or cooling is a
9-stage axial compressor with one centrifugal stage. It mainly comprises the following
components (see also Figure5-1):
• Main casing (2 parts)
• Stator blade carrier (2 parts)
• Axial rotor (see Fehler! Verweisquelle konnte nicht gefunden werden.)
The following figure shows the design of the compressor and the identification of the blades.
Smoothing chamber
ℵ ℑ

Stage 00 0 1 2 3 4 5 6 7
Rotor blades Guide vanes

1 Annular duct stage 3 2 Annular duct stage 6
Figure5-3: Compressor design and identification of the blades
a) Function
While flowing through the individual stages of the axial compressor, air is compressed
accordingly. The air temperature also increases by compression. The radial flow impeller of
the compressor rotor subsequently deflects the air jet by 90° and directs it over a diffuser that
initiates a reduction of the flow speed into the smoothing chamber (see Fehler! Verweisquelle
konnte nicht gefunden werden.). The smoothing chamber consists of the compressor stator
blade carrier casing and the GG main casing. From there, the major part of the air gets into
the combustion chambers via two elbows. The remaining air is routed on via ducts and bores
for cooling of the HP1 turbine stator blade serving as a drive unit for the compressor rotor.
2
1
1 Radial stage 2 HP turbine 3 Axial compressor

Figure5-4: GG rotor 1
3
b) Blades
The identification of the compressor stages (see Fehler! Verweisquelle konnte nicht gefunden
werden.) had to be adapted in the course of further developing the THM 1203 because the
compressor capacity was continuously increased by adding the stages 00 and 0. All
compressor blades are provided with a coating for corrosion protection. Teflon segments are
screwed to the tips of the stator blades of stages 00, 0, 1 and 2. The labyrinth strips at the
rotor discs of the compressor rotor penetrate the teflon in the course of the first operating
hours.
1 The figure shows a GG rotor of a THM 1304 with 10 compressor blade rows. There is no first
compressor blade row on the GG rotor of the THM 1203. Furthermore, the blades of the HP turbine do
not have shrouds in the area of the blade tips.

This kind of sealing makes it possible to minimize clearances and thus to keep the
performance and/or efficiency losses low.
The discs (into which the blades are inserted in dovetail slots), the radial flow impeller and the
shaft ends of the rotor (see Fehler! Verweisquelle konnte nicht gefunden werden.) are kept
together by 13 tie rods.
Table 5-1: Number of compressor blades
Level Stator blade Rotor blade
GG inlet 38 ---
00 52 21
0 50 23
1 46 26
2 58 31
3 66 37
4 74 43
5 78 61
6 78 67
7 70 67

c) Blow-off and cooling air system
Under certain operating conditions compressor air has to be removed via blow-off valves in
order to prevent surging of the compressor. For this purpose, the compressor stator blade
carrier provides radially running grooves between the 2nd and the 3rd as well as between the
5th and the 6th stage via which the compressor air is routed into two annular channels (see
Fehler! Verweisquelle konnte nicht gefunden werden.). The drawn-off air of stages 3 and 6 is
discharged via two blow-off valves installed on top of the GG main casing. The blow-off valve
installed on the bottom GG main casing half serves to remove the compressor air from the last
stage.

5.2.5 Combustion chambers
The two combustion chambers that are installed in V-shape on the upper GG main casing half
mainly comprise the following components:
• Casing with inlet elbow
• Flame tube
• Igniter
• Injection nozzle
The compressed air is routed into the combustion chamber casing via the smoothing chamber
and an elbow. Through the slots and bores in the flame tube the compressed air reaches the
combustion compartment where it is mixed with fuel and ignited by means of an igniter.
3 4
1 Fuel nozzle 2 Igniter
3 Elbow 4 Flame tube
Figure5-5: Design of combustion chamber

5.2.6 Gas collector
The gas collector (with grey background in the following figure) routes the hot waste gases
from the combustion chamber into the HP turbine. The gas collector is cooled from outside
with the air previously routed via the smoothing chamber into the combustion chambers for
cooling of the flame tubes. The lower section of the gas collector accommodates a drain port.
ℑ
Figure 5-6: Gas collector

5.2.7 HP turbine
The HP turbine of the gas generator (an axial-flow two-stage backpressure turbine) consists of
the following components (see Figure5-7):
• HP1 stator blade carrier
• HP turbine rotor
• HP2 stator blade carrier (in 2 parts, vertical split joint)
Figure5-7: HP turbine
The single-part HP1 stator blade carrier consists of one inner and one outer support ring as
well as 50 stator blades. The inner ring is bolted to the gas collector and the outer ring to the
GG main casing.
The HP turbine rotor consists of two discs and the 75 HP1 and 71 HP2 rotor blades which are
inserted in fir-tree-shaped grooves. The pair of discs is connected to the rear shaft end of the
compressor rotor by four centring pins and four bolts (see Fehler! Verweisquelle konnte nicht
gefunden werden.). For inspection of the hot gas parts, one carrier half can be removed (after
the gas generator and the LP turbine have been shifted apart).
Table 5-2: Number of blades on HP turbine
Level Stator blade Rotor blade
1 50 75
2 80 71
The second row of blades of the HP stator blade carrier
consists of blade segments with 3 blades each.

5.2.8 Support of the GG rotor
The GG rotor is supported in two hydrodynamic sleeve bearings. With this bearing type, the
lube oil pressure required for supporting the shaft is generated by the rotary movement of the
GG rotor. With increasing speed, more and more oil is transferred from the contact surface of
the shaft into the lubrication gap. As a result, the oil pressure in the lubrication gap rises until
the shaft floats on the lube oil film.
The GG front bearing comprises one thrust, end thrust, and sleeve-type journal bearing each.
During start-up the end thrust bearing absorbs the axial force acting opposite to the direction
of flow. At higher speeds, the conditions of the axially acting forces change and the rotor is
pressed against the thrust bearing in the direction of flow.
Figure 5-8: GG front bearing

Sealing towards the compression chamber at the rear end of the GG front bearing is made via
a floating ring sliding on the shaft end of the GG rotor and via a labyrinth seal. The required
seal air is routed through bores from the inner area of the compressor rotor to the labyrinth
seal.

Figure 5-9: Front GG bearing

The GG rear bearing like the GG front bearing is of two-part design. However, it consists of
one sleeve bearing only, the design of which is similar to that of the GG front bearing. Other
than in the case of the GG front bearing, sealing at both ends of the bearing is made via

floating rings and labyrinth seals. The seal air is routed through the inner area of the
compressor rotor and through bores to the labyrinth seals.
Supply of lube oil to the GG front bearing is made through a line connected to the GG inlet
casing. Through internal ducts and pipes, the oil is fed into the annulus of the bearing and
injected there. The oil then gravitates from the bearing over the lower strut of the GG inlet
casing into the lube oil reservoir.
The pipe for lube oil supply to the GG rear bearing is connected to the lower GG main casing
half in the rear area. The oil is injected in the same way as on the GG front bearing through a
hose and internal ducts inside the gas generator. By gravitational force the oil flows into a
collecting chamber and from there through a hose that is likewise inside the gas generator
back into the lube oil reservoir.
Figure 5-10: Rear bearing GG

Figure 5-11: GG rear bearing Assy

5.3 Power turbine
The power turbine or LP turbine (an axial-flow two-stage backpressure turbine) transforming
the energy contained in the waste gas coming from the gas generator into a rotary movement
and transferring it to the processing machine via the drive coupling consists of the following
components (see Fehler! Verweisquelle konnte nicht gefunden werden. and Fehler!
Verweisquelle konnte nicht gefunden werden.):
• LP stator blade carrier (in 2 parts, vertical split joint)
• LP turbine rotor
• LP casing (4 parts)
• Exhaust elbow
Table 5-3: Number of blades on LP turbine
Stage Stator blade Rotor blade
1 34 61
2 70 51
5.3.1 LP turbine rotor / LP stator blade carrier
The gas generator is connected to the power turbine via the inlet flange of the two-part LP
stator blade carrier. The LP carrier accommodates among others the six T4 thermocouples
for monitoring of the LP inlet temperature as well as the LP1 and LP2 stator blades.
For inspection of the hot gas parts, one carrier half can be removed (after the gas generator
and the LP turbine have been shifted apart).
The LP turbine rotor consists of two discs and the 61 LP1 and 51 LP2 rotor blades which are
inserted in fir-tree-shaped grooves. The pair of discs is connected to the LP shaft via four
body-bound studs and four bolts. The shaft is connected to the output coupling which
transmits the torque to the driven machine.

1 2
2
1 T4 thermocouple
2 LP1 stator blade carrier casing
3 LP1 stator blade
5
4 LP2 stator blade
5 LP turbine rotor
Figure5-12: LP1 stator blade carrier casing

5.3.2 LP main casing / exhaust elbow
The tapered LP main casing consists of an internal and an external casing which are
connected to each other by four struts. The internal casing accommodates the two bearings
for supporting the LP rotor. Two brackets are cast to the external casing providing the
connection to the base frame.
The LP main casing functions like a diffuser and permits an almost loss-free reduction of the
exhaust gas velocity. It routes the exhaust gases from the LP turbine via the exhaust elbow to
the exhaust stack or to a heat recovery system.
3 4
1 LP main casing 2 Strut 5 3 Front bearing

4 LP shaft 5 Rear bearing
Figure5-13: LP main casing

5.3.3 Support of LP turbine rotor
The LP turbine rotor is supported by two hydrodynamic sleeve bearings the design and
functioning of which is similar to that of the GG bearings (see section 5.2.8). Other than in the
case of the GG rotor, the thrust, end thrust, and sleeve-type journal bearings are arranged at
the rear shaft end.
Sealing towards the LP turbine at the front end of the LP front bearing is ensured by a floating
ring which slides on the shaft end of the LP rotor and via a labyrinth seal. There is no sealing
at the rear end of the LP front bearing. External cooling air is used as seal air for the labyrinth
seal. No floating ring and/or labyrinth seal is installed on the LP rear bearing.
Supply of lube oil to the two LP bearings is made through a pipe connected to the LP rear
bearing housing. Part of the oil flows directly into the LP rear bearing while the remaining oil
flows to the LP front bearing through an internal pipe. Oil injection in the bearing is made in the
same way as on the GG bearings. The oil from the LP front bearing then gravitates into the
internal casing of the LP main casing. Approximately half of the oil from the LP rear bearing
also flows into the internal casing. The remaining oil flows into the coupling guard. The oil then
returns through the pipe connected to the internal casing and/or to the coupling guard into the
lube oil reservoir.
Figure5-14: Lube oil connections on the LP turbine

6 Base engine instrumentation
Brief description
Regarding TAG numbers, observe the current P&I diagrams in the Operating Instructions for
Machine Unit.
The instrumentation of the base engine (see Figure6-1, 5-2, 5-3) mainly comprises the speed,
pressure, casing vibration, bearing (axial displacement) and temperature measuring devices
which are installed on gas generator and power turbine and which are required on the one
hand for control purposes and on the other hand for monitoring of the gas turbine.
1 2 3 5 6
2
1 Drive coupling with gear wheel for speed measurement of GG rotor
2 front GG bearing with bearing monitoring (axial displacement)
3 rear GG bearing
4 PT inlet temperature measurement (arrangement see Figure6-6)
5 front PT bearing
6 rear PT bearing with keyphasor, bearing monitoring (axial displacement),
speed measurement
Figure6-1: Location of base engine measuring points3
2 Location of GG speed measurement for units with auxiliary gear unit.

3 The Figure shows a gas generator with standard combustion chambers.
Version 01- 2011 Base engine instrumentation

Figure6-2: Instrumentation of front GG bearing (2*Z-probes)
Base engine instrumentation Version 01-2011

Figure 6-3: Instrumentation of rear PT bearing

6.1 Speed measurement (nGG, nPT)
The main components of the speed measuring facility are five inductive speed sensors and
five overspeed protection relays. The speed sensors are installed in the area of the turbo-
starter auxiliary gear unit and in the rear area of the PT bearing .
The speed sensors generate a frequency proportional to the number of impulses which are
generated on the gas generator by means of a gear wheel and on the power turbine by means
of a shaft toothing (number of teeth = 60).
On units with a lateral auxiliary gear unit, the gear wheel (number of teeth = 102) for impulse
generation is located in the lateral gear unit. The speed sensors are installed on the casing
(see Figure6-4).
If the start-up system is equipped with a front gear unit (for driving a mechanical lube oil pump)
the speed sensors are installed on this gear unit (see Figure6-5). In this case, the impulses
are generated by a gear wheel with 70 teeth.
Two speed signals are picked up for each rotor (GG, PT); the signal coming from the sensors
is processed by the GT control system and the other one by the overspeed protection relay.
The PT sensors are connected on the PT main casing up to a terminal box mounted on the
baseframe of the turbine.
Figure6-4: Arrangement of GGspeed sensors (lateral gear unit)

1 2
A
Gas generator
1 auxiliary gear unit

2 drive coupling
3 Fitting plates for GG speed sensors
Figure6-5: Arrangement of GG speed sensors (start-up system with auxiliary gearbox)
6.2 PT inlet temperature measurement (T4)
Measurement of the PT inlet temperature mainly comprises 3 double thermocouples per end,
each of which is connected to a temperature transmitter.
Measurement also serves to monitor the ignition process, to protect the gas turbine unit
against excessive combustion and to measure individual and/or average values, which are
necessary to control the gas turbine unit.
Two thermoelectric voltages are generated for each thermocouple (use of a duplex element).
Both measurements are passed on to the unit control panel via one temperature transmitter
each and connected to the Allen Bradley control system. The recorded temperature signals
are used by the gas turbine control system among others for determination of the average
value and for controlling the gas turbine temperature.
Arrangement of the thermocouples in the LP1 stator blade carrier casing of the power turbine
is shown in Figure6-6. There is a total of 12 ports in the LP1 casing, 6 of which are closed by
blind flanges and are not identified by a TAG code in the Figure below.

TE-404.1.1 TE-404.3.1
TE-404 1 2 TE-404.3.2
TE-404.4.1
TE-404.12.1 TE-404.4.2
TE 404 12 2
TE-404.6.1
TE-404.10.1
TE 404 6 2
TE-404 10 2
Figure6-6: Arrangement of the T4 thermocouples (shown in the direction of flow)

4
2 3
1
1 T4 cable 2 thermocouple element 3 protective sleeve

4 LP1 casing 5 HP2 casing
Figure6-7: Installation position of a T4 thermocouple
6.3 Vibration measurement
For monitoring of gas turbine vibrations, one vibration detector each is installed on the GG
casing (Figs. 2-2 and 2-4) and on the PT casing.
Fig. 2-8 PT casing vibration sensor

6.4 Phase angle measurement
Phase angle measurement comprises one keyphasor sensor, one signal transducer
(proximitor) and one electronic card.
The keyphasor is located in the rear PT bearing section. On the PT main casing, the sensor
cabling is routed to the signal transducer. The electronic card for analysis is a component of
the vibration monitor which is installed in the vibration monitoring cubicle.
The keyphasor is a position transducer or a capacitive proximity sensor which once every
revolution generates a voltage signal via a square bar or pin fastened on the PT shaft; this
signal is transmitted to the vibration monitor via a signal transducer. The keyphasor signal
serves for illustrating the relation between speed and vibration frequency.
6.5 Wear measurement on thrust bearing
Wear measurement on thrust bearing comprises 2 capacitive proximity sensors and 2 signal
amplifiers (proximitors).
Two sensors for monitoring axial wear on the thrust bearing are arranged in the front GG
bearing section (see Figure6-2) and in the rear PT bearing section (see
Figure 6-3).

The electronic cards for evaluation are a component part of the vibration monitor which is
installed in the vibration monitoring cubicle.
Due to the axial movement of the rotor the oscillating circuit created by the sensor coil is
dampened considerably, i.e. the cyclic stress is greatly reduced. The generated negative
voltage signal is proportional to the distance between sensor and shaft.
Warning
Work on base engine components may only be carried out
during standstill and after a cool-down period of several
hours. Prior to the performance of service and maintenance
measures the following Sections in Chapter 1 General
safety information [J 1 | 1] shall be observed:
measures [J 1 | 4]
[J 1 | 6]
6.5.2 Inspection
Routine inspections and walk-around checks have to be carried out
regularly. Additionally, an annual major inspection of the described system
is recommended.
Routine inspections / walk-around checks [J 3 | 19]


7 Fuel gas system


The fuel gas system mainly comprises: trip and vent valves, fuel gas filter,
solenoid valves, monitoring instruments (e.g. for pressure, temperature,
etc.) as well as two fuel gas control valves.
The fuel gas system in conjunction with the GT control system supplies the
gas turbine with fuel gas during start-up and subsequent operation.
Further, it warrants immediate isolation of fuel gas supply especially in the
case of trips (e.g. due to overtemperature and overspeed conditions or
component malfunctions).
The fuel gas flows through filters and trip valves to the two control valves.
The fuel gas flow rate is adjusted by reference to the operating condition
and to the gas turbine power output setting, and the fuel gas routed to the
three gas systems of the two burners (which are part of the combustion
chambers).
The two fuel gas control valves are arranged in the vicinity of the burners
to keep the fuel gas volume enclosed between valve and burner low. In
the case of rapid load changes this has a positive effect on the gas turbine
control behaviour – especially with regard to the avoidance of flame
instabilities.
In the event of a gas turbine unit trip, the fuel gas trip valves are closed,
the vent valves are opened and the gas present in the pipes is discharged
through vent pipes.
7.1.2 Fuel gas specification
7.1.2.1 General
This fuel gas specification defines the requirements for gaseous fuels to
be used in THM gas turbines. Natural gases with a methane content of
more than 80% by volume are used by preference. Generally, the limit
values for physical and chemical properties listed in the table below have
to be adhered to.
Gaseous fuels which do not meet the limit values given in the table may
possibly be approved for THM gas turbines nonetheless. For this,
however, the technical department of MAN DIESEL & TURBO SEhas to
make a detailed assessment of these values. By special protective
measures carried out on gas turbine component parts it may become
permissible to exceed individual limits. In the case of gas turbines which
are equipped with Dry-Low-NOx (DLN) combustion chambers further limit
values have to be observed to ensure trouble-free operation.
Fuel gas system Version 01-2011

When assessing the gas analysis especially those substances have to be
considered which can lead to corrosion, e.g. alkaline metals (sodium,
potassium, etc.) or sulphur compounds so that adequate steps can be
taken for minimizing corrosion in the gas turbine or the fuel system.
In addition to assessment of the gas analysis and of impurities contained
in the fuel gas envisaged for operation, customer is urgently
recommended to set up a suitable system for fuel supply and conditioning
as well as for monitoring the fuel gas quality.
The table specifies limit values for the concentration of various impurities.
Further possible sources of impurities are the inlet air, and, if applicable,
the water which is injected into the combustion chamber. The limit values
in the table are valid on the assumption that additional impurities will not
be added through air or water. If this should be the case, however, the
limit values for fuel gas have to be reduced for each component as shown
in the following formula:
Cmax, corrected = Cmax, table - AFR x Cair - WFR x Cwater
Cmax,corrected = Corrected max. permissible concentration

Cmax, table = Maximum permissible concentration from the table
Cair = Expected concentration in the air
Cwater = Expected concentration in the injection water
AFR = Mass flow ratio air to fuel (typically approx. 60 : 1)
WFR = Mass flow ratio injection water to fuel (typically 0.5 - 1.0 : 1)
7.1.2.2 Physical and chemical minimum properties profile of

gaseous fuels
Fuel gas properties
Property Limit value Test method

Lower heating value (LHV) 31 - 48 MJ/mN3 *)
Wobbe Index (Note 1) 40 - 53 MJ/mN3 *)
Admissible variation of heating ± 10%
value and Wobbe Index with set
control
Methane content (CH4) min. 80% by vol. (only DLN)
Content of hydrocarbons C3 or max. 4.0% by vol. (only DLN)
heavier
Version 01- 2011 Fuel gas system


Hydrogen content (H2) max. 1.0% by vol. (only DLN)
max. 60% by vol.
(standard combustion chamber)
Ratio of upper to lower quenching min. 2.2 (only DLN)
limit
(at 101.3 kPa, 25 °C)
Water content (H2O) (Note 2)
Dust particle impurities: max. 20 ppm wt ISO 3735
Particle diameter > 10 mm 0% by vol.
Particle diameter 2 - 10 mm 10% by vol.
Impurities with corrosive effect :
Total sulphur content max. 100 ppm vol. (without ISO 8754
special coating)
max. 1.5% by vol.
(with special coating in the
turbine section)
(Note 3)
Sodium + potassium max. 0.5 ppm wt DIN 51797
*) mN³ referred to standard conditions (0 °C, 101.3 kPa)
Note 1
Wobbe Index (corrected to 15 °C) =
T = Fuel gas temperature [°C]

d = Ratio of standard density of fuel gas to standard density of air
Hu = Lower heating value [MJ/Nm³]
Note 2
The water content must not exceed a max. concentration during which gas
hydrates might develop immediately upstream the fuel gas control valve,
taking into consideration the fuel gas temperatures, pressures, and
compositions which are possible during operation. Gas hydrates are not
allowed. Heating up of the fuel is permissible.
Note 3
Sulphur dioxide (SO2) develops through combustion of sulphur
compounds in the fuel gas. The total sulphur content must therefore be

limited to such an extent that compliance with the emission limit values
specified by the local approval authorities is ensured.
Among other elements, the total sulphur contains sulphur hydrogen (H2S),
mercaptanes, carbon disulphide (CS2), carbonyl sulphide (COS),
tiophenes, and sulphur oxides.
7.1.2.3 Fuel gas pressure

The following table contains limit values which have to be maintained at
the inlet of the fuel gas control valve, i.e., downstream of the gas pressure
control instrument.
Fuel gas pressure at the inlet to the fuel gas control valve

Minimum fuel gas inlet pressure
(Note 4) :
THM 1203 approx. 1.5 MPa (absolute)
THM 1304-10 approx. 1.8 MPa (absolute)
THM 1304-11 approx. 2.0 MPa (absolute)

Maximum admissible fuel gas inlet 3.1 MPa (absolute)
pressure
Admissible pressure variation ± 2,5% DIN 3380
Admissible hysteresis of fuel gas 4% DIN 3380
pressure
Admissible deviation of fuel gas 15%
pressure from setpoint value at
minimum flow rate
Admissible transient pressure max. 0.2 bar/s
change
Note 4
The minimum fuel gas inlet pressure given in the table refers to ISO
conditions (15 °C air inlet temperature, sea level, no pressure losses).
The fuel gas inlet pressure required in each respective case depends on
the installation and operating conditions and also on the fuel gas
composition. Calculation for a specific project can be made by MAN
TURBO AG.

7.1.2.4 Fuel gas temperature (gas turbine inlet)

Liquid constituents in the fuel gas are not allowed. The minimum
temperature must be 20 K above the dew point of heavy hydrocarbons
and 20 K above the dew point of water.
Limit values for the fuel gas temperature
Property Limit value

Minimum fuel gas temperature 50 ℃
Maximum dew point temperature 50 ℃
Maximum fuel gas temperature 70 °C *)
Admissible transient temperature change max. 4 K/min
*) With minor modifications to the fuel gas system 90 °C are also acceptable.
7.1.3 Inspection
is recommended.
7.1.4 Repair
General information relating to the replacement of component parts (e.g.
pressure switches, pressure sensors, limit switches, thermometers,
pressure gauges, valves, etc.) not included in the present system
description will be found in Chapter “General service and maintenance
information”. Should any further information be required, please contact
the MAN DIESEL & TURBO SE After Sales Service.
General notes on the exchange of component parts [J 3 | 4]
piping. The valve position is monitored by limit switch. A solenoid valve is

provided for activation of each vent valve.

7.2 Gas control valve

The gas control valve installed inside the noise control enclosure serves to
control the fuel gas mass flow during load operation of the gas turbine.
With reference to the GT performance set by the machine operator a
stepping motor is actuated amongst others by the GT control The gas
control valve consists of the control valve proper, a stepping motor, a limit
switch, and a position monitor.
Actuated by the stepping motor the gas control valve is opened and the
fuel gas flows to the two burners where it is mixed with the compressor air
and ignited.
The actual position of the control valve detected by the position sensor is
processed by the GT control system. Under certain operating conditions a
limit switch initiates an alarm if the control valve is not closed.
For calibration of the control valve, switches are provided on the GT
control panel for manual operation of the gas control valve. During
calibration, the position of the valve can be read from a scale directly fitted
on the valve.

Premix / diffusion gas control valve
1 Terminal box 6 Solenoid pilot valve for trip valve

2 Repeater 7 Stepping motor
3 Ignition gas release valve 8 Terminal box
connection *
4 Vent port 9 Trip valve
5 Vent valve 10 Balancing connection
* The Figure shows a dummy flange instead of the ignition gas release valve.

8 Ignition system

The main components of the ignition system comprise four ignition
electrodes and two high-voltage ignition transformers. Two ignition
electrodes each are arranged in the burner of the combustion chamber.
The ignition system is designed for igniting the fuel/air mixture in the two
combustion chambers during the start-up process of the gas turbine.
8.1.1.1 Ignition process

After completion of the purging operation which serves for removing gas
residues from the gas turbine interior, the following sequence is initiated.
The sequence description is based on plant units which are equipped with
two vent valves and two trip valves. For plant units which are equipped
with just one vent valve and one trip valve the described sequence is the
same except for the different number of valves.
a) The instrument air solenoid valves are changed over and the vent and
trip valves opened. For approx. 10 to 30 seconds gas flows through the
vent valves for purging impurities (especially condensate) from the fuel
gas piping.
b) The instrument air solenoid valves for activation of the two vent valves
are changed over and the vent valves are closed.
c) The ignition transformers for supply of the four ignition electrodes are
cut in.
d) The diffusion/premix gas control valve is opened, the fuel gas flows to
the ignition electrodes, is mixed with compressed air, and ignited.
e) With the pilot flame radiating into the burner, fuel gas flows via the
diffusion gas / premix gas control valve to the various nozzle systems of
the two burners. Here, the fuel gas is mixed with the compressor air and
the air/fuel mixture is ignited (main flame).
f) When the gas generator idling speed is reached, gas is routed to the
pilot burner nozzles via the pilot gas control valve.
g) The ignition electrodes are cut out when the main flame has been
detected or, at the latest, approx. 20 seconds after ignition has been cut
in.
h) During stepwise acceleration of the GG rotor, several checks are made
to verify that the GG rotor reaches the specified speeds within the
defined periods. If the required speed is not reached, the start-up
procedure is aborted.
Version 01- 2011 Ignition system

Warning
The service and maintenance measures described in the
following must only be performed with the gas turbine unit at
standstill and cooled down.
Prior to the exchange of any components, the ignition
system must be safely isolated from the supply voltage. If
this is not observed, there is the risk of an electric shock
owing to the extremely high voltage. Work on the ignition
system may be carried out at the earliest 30 minutes after
voltage supply has been discontinued to permit the stored
charge to decay.
Prior to performance of service and maintenance measures
the following Sections in Chapter shall be observed:
measures [J 1 | 4]
[J 1 | 6]
General safety information [J 1 | 1]
8.1.3 Inspection
is recommended.

8.1.4 Ignition test

For checking proper functioning of the ignition system a program
sequence is envisaged which can be selected via button "ignition test" on
the GT control panel. The following sequence description is based on a
fuel gas system with two vent and trip valves. The sequence is identical for
plant units with just one vent and trip valve.
For initiating the sequence the following steps have to be carried out:
1. Observe the general safety information given in the system description.
2. Actuate button "ignition test".
3. Actuate button "... start-up preparation".
4. Actuate button "… pressurization" (only for plant units with compressor).
Ignition system Version 01-2011

5. Actuate button "... start".
Note: When purging for the removal of gas residues from the gas
turbine interior has been carried out, the following sequence steps are
initiated for checking proper functioning of the ignition system.
6. The instrument air solenoid valves are changed over and the vent and
trip valves opened. For approx. 10 to 30 seconds gas flows through the
vent valves for purging impurities (especially condensate) from the fuel
gas piping.
7. The instrument air solenoid valves for activation of the two vent valves
are changed over and the vent valves are closed.
8. The ignition transformers for supply of the ignition electrodes are cut in.
9. The fuel gas control valve is opened. The fuel gas flows to the ignition
electrodes. In the area of the ignition electrodes the fuel gas is mixed
with compressor air and ignited.
10. Proper functioning of the ignition system can be assessed by
reference to the slight rise in the T4 temperature (approx. 5 to 8 °C / 41
to 46.4 °F) or to the noise developed by the ignition transformers.
11. The ignition test is complete when the fuel gas trip valves close,
the fuel gas vent valves open, and the ignition transformers are cut out.
12. Unless the gas turbine is then stopped and button "ignition test"
actuated once more, the start-up procedure is continued with repetition
of the purging operation.
13. If ignition problems should still occur, please contact the Service
Department of MAN TURBO AG.
8.1.5 Repair
8.2 Ignition electrodes

Details about the ignition electrodes will be found in the description of the
combustion chamber.
Version 01- 2011 Ignition system


8.2.2 Repair
For exchange of an ignition electrode the combustion chamber dome has
to be dismantled and the burner removed. Since special know-how is
required in particular for subsequent re-installation of the burner, the work
must only be carried out by appropriately trained and authorized
personnel.
Ignition system Version 01-2011

9 Blow-off and instrument air systems
9.1 Blow-off valves

The three blow-off valves are almost identical in design. However, the
valves of stages 3 and 6 are additionally equipped with a spring ( 4 ). The
spring supports the opening action of the valve to ensure that it is fully
open.
The compressor air taken from the radial stage is routed via a port ( 1 )
into the control chamber of the blow-off valves. The valve stem which is
connected to a rubber diaphragm is forced down and keeps the valve
closed. If air supply to the control chamber is interrupted by closing of the
associated solenoid valve, the valve is opened by the compressor air
acting on the valve plug. When the gas turbine is at a standstill, the valve
is kept open by the diaphragm (with some support by the spring).
Design of blow-off valve
1 Compressor air (radial stage) 4 Spring

2 Diaphragm 5 Valve plug
3 to the atmosphere 6 from the compressor
Version 01-2011 Blow-off and instrument air systems

9.1.2 Replacement
Caution
Risk of damage to the gas turbine!
As the blow-off valves are of identical external appearance,
special care must be taken to ensure that the correct valve
is installed. Refer to the spare parts catalogue for
unambiguous identification. Installation of a blow-off valve in
the wrong location may lead to gas turbine damage.
Z Observe the general safety information given in the system description.

1. In view of its weight, the blow-off valve to be removed must be
suspended from the noise control enclosure crane using a suitable
hemp rope.
2. Loosen the screw connections on the blow-off valve (piping, GG main
casing).
3. Use the enclosure crane to handle the defective and the new valve.
4. Apply graphite paste Never-Seez to the blow-off valve fastening bolts.
5. Use new seals when screwing down the blow-off valve.
6. Note: Observe the "Tightening torques for base engine connections" in
Chapter "General service and maintenance information".
9.2 Solenoid valves (for activation of blow-off valves)

The electrically actuated and directly controlled 3/2-way solenoid valves
are provided for activating the blow-off valves. Activation of the solenoid
valves is made as a function of the GG speed.
The solenoid valves are mounted on a rack inside the noise control
enclosure on the right-hand side (view in direction of flow) next to the GG
inlet casing.
Blow-off and instrument air systems Version 01-2011

Ports on the solenoid valve
1 Port 1: Control chamber vent

2 Port 2: To control chamber of blow-off valve
3 Port 3: From compressor (radial stage)
9.3 Pressure sensors compressor discharge pressure / PT

inlet pressure

The pressure sensors for measuring and monitoring the compressor
discharge pressure (P2) and the PT inlet pressure (P4) are dedicated to
the blow-off and instrument air systems.
The pressure sensors are mounted on the instrument rack which is
located in the right-hand front area of the noise control enclosure (view in
direction of flow).
For further details refer to the Instrument List.
9.4 Pressure transducer
9.4.1 Subcontractor documentation

Subcontractor PMCS engineering documents will be found in the separate
PMCS Documentation.
Version 01-2011 Blow-off and instrument air systems

10 Cleaning system

The main components of the cleaning system include the offline cleaning
nozzles (4 off) located in the GT intake elbow, which are interconnected
through a ring line, and a mobile cleaning unit.
In addition to the cleaning nozzles, two nozzles for the injection of a
preservation fluid are installed in the intake elbow. Since dry air
preservation is preferable to wet preservation, the preservation nozzles
are not used any longer.
The cleaning system serves to clean the gas generator interior. Impurities
deposited on the blades are removed by regular cleaning, counteracting
deteriorations in the performance and efficiency of the gas turbine unit.
Above that, frequent compressor cleaning reduces the risk of corrosion
damage and also the fuel consumption.
The performance level and the efficiency of a gas turbine unit in the as-
new state can, however, not be regained by cleaning because of the
normal wear resulting from operation (e.g. in the area of seals and
blades). The original level can only be restored by extensive works repair
measures. For information about the expected course of deterioration of
efficiency and performance refer to the diagrams / curves in the Operating
Instructions.
10.1.2 Time of cleaning

The time of cleaning depends on the site conditions and the associated
soiling as well as on the operational experience. Above that, the time of
cleaning depends on the extent of performance deviation which, as a rule,
is indicative of soiling of the gas generator compressor.
We recommend to initially clean the gas generator at least once a month.
For determination of the site-specific cleaning interval, the performance
shall be recorded before and after cleaning at comparable suction
temperature and comparable suction pressure. If the improvement in
performance after cleaning should only be slight, the cleaning interval may
be extended. If the improvement in performance is significant, the cleaning
interval has to be shortened appropriately.
With a high salt content in the intake air, daily cleaning is recommended. If
continuous operation does not allow this, cleaning is required at least once
per week. This also applies if the unit has not been in operation before.
Cleaning of the gas generator compressor is also required prior to long
standstill periods for removing corrosive deposits.
Version 01-2011 Cleaning system

10.1.3 Use of cleaning additives

Cleaning additives have to be used for improving the cleaning efficiency,
especially in the case of oily deposits and deposits insoluble in water.
No other than the cleaning additives approved by MAN DIESEL & TURBO
SEmay be used (see Section 10.1.6.3 Approved cleaning additives
[J 10 | 4]).
U Caution
Hazard to health from cleaning additives!
In order to avoid hazards to the health of personnel, the
safety instructions by the respective cleaning additive
supplier must be observed.
For preparation and processing of the cleaning solution, the information

provided by the supplier of the cleaning additive shall be observed.
10.1.4 Use of antifreeze
10.1.4.1 Risk of frost during cleaning

In order to avoid freezing of the pumps and lines during cleaning when
there is a risk of frost, isopropyl alcohol (IPA) or ethylene glycol shall be
added to the cleaning solution or to the wash water. The following table is
based on a mixing ratio of 1 : 4 (cleaning additive / water).
Mixing ratios
Ambient temperature Cleaning additive Water/IPA Water/glycol

°C °F % by vol % by vol % by vol
above +5 above 41 20 80 / 0 80 / 0
+5 to -5 41 to 23 20 60 / 20 60 / 20
-5 to -20 23 to -4 20 30 / 50 40 / 40
-20 to -30 -4 to -22 20 10 / 70 30 / 50
-30 to -40 -22 to -40 20 --- 20 / 60
Caution
Performance losses and damage to the blading!
Icing on the blades from frozen cleaning solution or wash
water may result in performance losses and damage to the
blading!
10.1.4.2 Risk of frost after cleaning

In order to avoid freezing of the cleaning system after cleaning, all water
lines and components of the cleaning system have to be drained. For this,
the hand shut-off valves which must be kept closed during the cleaning
Cleaning system Version 01-2011

phase have to be opened. During standstill of the cleaning system the
valves of this system must be kept open, to ensure that water which might
possibly freeze does not remain in the system.
10.1.5 Cleaning sequence

After the gas turbine has cooled down (PT inlet temperature T4 < 65 °C)
and the preparatory measures have been completed, the following
cleaning sequence steps may be initiated via the operator panel on the GT
control cabinet.
Step 1: Injection of cleaning solution with subsequent soaking.

Step 2: Injection of clear water for flushing out the cleaning solution.
Step 3: Ventilation of gas turbine for drying the internals.
Step 4: 15-minute load operation for drying the internals.
The cleaning sequence (steps 1 to 3) basically is a start-up process, but

without the ignition being cut in and with the inlet guide vanes fully open.
Above that, the blow-off valves are kept closed by instrument air instead of
GG compressor air. Depending on the degree of soiling, steps 1 and 2
have to be repeated several times.
10.1.6 Wash water specification / approved cleaning additives
10.1.6.1 Scope
This specification stipulates the approved cleaning additives and the
requirements concerning the minimum properties profile of the wash water
used for cleaning the gas generator compressor in gas turbine units of
MAN TURBO AG.
10.1.6.2 Minimum properties profile of wash water

Fully demineralized water (deionate) of high purity should be used for
cleaning the gas generator compressor in order to avoid corrosion and
erosion.
Since full compliance with these stringent quality requirements is often
difficult to achieve at the installation site, the following water parameters
are regarded as being still tolerable.
Physical and chemical minimum properties profile of the wash water
Property Limit value Unit

pH value at 20 ℃ 6.5 to 8.5 pH
Conductivity at 20 ℃ ≤ 50 µS/cm
Chlorides ≤ 10 mg/l
Sulphates ≤ 10 mg/l
Total hardness ≤1 mg CaO/l

Property Limit value Unit

SiO2 content ≤1 mg/l
Total dissolved substances ≤ 30 mg/l
Solid foreign matter ≤5 mg/l
10.1.6.3 Approved cleaning additives

The following cleaning additives may be used for online as well as offline
cleaning:
■ Turbo-K
■ ZOK 27
Information about procurement of these products is available from the
competent After Sales Service department of MAN Diesel & Turbo SE.

Warning
Cleaning of the gas generator compressor may be carried
out only with the gas turbine unit cooled down.
safety instructions by the respective cleaning additive
supplier must be observed.
At ambient temperatures below +5 °C (41 °F) an antifreeze
must be used.
The pump of the mobile cleaning unit must not on any
account be run without water - not even for checking.
The service and maintenance measures described in the
following must only be performed with the gas turbine unit at
standstill and cooled down. Prior to the performance of
service and maintenance work observe the following
Sections in Chapter 1 General safety information [J 1 |1]
measures [J 1 | 4]
[J 1 | 6]
10.1.8 Measures to be taken before initiating the cleaning

sequence
U Caution
Warning of hazard to health!
Cleaning of the gas generator compressor may be carried
out only with the gas turbine unit cooled down. Hazard of
burns!
relevant safety information by the respective cleaning
additive supplier and the references included in Chapter
"General safety information" shall be observed.
Caution
Risk of damage to plant unit components!
At ambient temperatures below +5 °C (41 °F) an antifreeze
must be used.
Before starting up the cleaning unit, the pump has to be
vented (see Service and Maintenance Instructions for Gas
Turbine – Cleaning System – Mobile Cleaning Unit). The
pump of the mobile cleaning unit must not on any account
be run without water - not even for checking.
Z For carrying out the following tasks, P&I Diagram "Auxiliary air /
Cleaning" and/or "Draining" (if available) may have to be consulted.

Approx. 50 l (13 gallons) of cleaning solution are required for one

cleaning operation.
1. Remove the plugs from the header of the instrument air system.
2. Flexible hoses for compressor cleaning were included in the scope of
supply. They have to be connected to the instrument air header and to
the solenoid valves provided for activation of the blow-off valves (see
P&I Diagram “Auxiliary air / Cleaning“).
Note: Since GT compressor air is not available during standstill of the
gas turbine, the blow-off valves have to be kept closed by instrument air
from an external supply source to prevent a major portion of the
cleaning solution escaping via the blow-off valves.
3. Open the instrument air supply.
4. For draining the GT compressor open ball cock V141.1 (see P&I
Diagram “Draining“ or “Auxiliary air / Cleaning“).
5. Connect the hose of the mobile cleaning unit to port Q1 of the ring line
on the GT compressor inlet casing.
6. Verify that the drain valve of the mobile cleaning unit is closed and that
the mobile cleaning unit is in safe condition. Clean the tank, if
necessary.
7. Check further that the vent screw in the pump head and the drain plug
in the lower pump section are screwed in.
8. Fill the cleaning unit mixing vessel with the required amount of water.
Note: At an ambient temperature below +5 °C (41 °F) the amount of
water to be filled in is less, since antifreeze has to be added (see
Service and Maintenance Instructions for Gas Turbine - Cleaning
System - Use of Antifreeze).
9. Add the cleaning additive.
Note: Observe the mixing ratio specified by the supplier.
10.1.9 Performance of cleaning

The cleaning procedure is described in the Operating Instructions for
Control Panel.
10.1.10 Measures after cleaning

1. Remove the cleaning unit connections from the gas turbine.
2. If there is the risk of frost, the cleaning unit must be drained thoroughly
by opening the drain valve in order to avoid damage to component
parts.
3. Shut off instrument air supply.
4. Close ball cock V141.1 (see P&I Diagram “Draining“ or “Auxiliary air /
Cleaning“).

5. Remove the hoses installed on the instrumentation and blow-off system
for the cleaning process and close the openings at the instrument air
end with the corresponding plugs.
Note: The pipes of the blow-off system must not be closed in order to
ensure ventilation of the control chamber of the blow-off valves and as
such proper functioning of the blow-off system.
6. Empty the drainage vessel. Disposal of the accumulated liquid must be
carried out properly in compliance with the laws applicable at the site
location.
10.1.11 Checking of cleaning result

The cleaning result can be checked using the following methods:
■ Visual inspection of the blades by means of an endoscope.
■ Analysis of fouled cleaning water for non-water-soluble substances
and/or analysis of conductivity.
If the result is not satisfactory, clean the gas generator compressor once
again.
10.1.12 Repair
10.2 Cleaning nozzles

The ring line with 6 nozzles (4 for cleaning and 2 for preservation) installed
on the intake elbow serves for offline cleaning. Although the preservation
nozzles originally envisaged for wet preservation of the base engine are
installed, they must not be used, since dry preservation is preferable to
wet preservation.

Design and location of cleaning nozzles
1 Intake elbow 2 Cleaning nozzle

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Service and Maintenance Instructions for Gas Turbine

THM 1203 5,6

MAN Diesel & Turbo SE

3 General service and maintenance information .................................... 1

Version 01-2011 General safety information

3.11 Use of graphite pastes .............................................................. 3

4 Base frame .........................................................................................1

General safety information Version 01-2011

1|2-2 © MAN Diesel & Turbo SE TGS_ O32410018

6 Base engine instrumentation ............................................................ 23

7 Fuel gas system ............................................................................... 32

8 Ignition system ................................................................................. 39

Version 01-2011 General safety information

8.2 Ignition electrodes ................................................................... 41

9 Blow-off and instrument air systems ...................................................1

10 Cleaning system .................................................................................1

General safety information Version 01-2011

1|4-4 © MAN Diesel & Turbo SE TGS_ O32410018

1.1 Types of references

Version 01-2011 General safety information

1.2 Safety information

1.2.1 Purpose of machine unit

General safety information Version 01-2011

1|2-2 © MAN Diesel & Turbo SE TGS_ O32410018

1.2.3 Improper use

1.2.4 Operating Instructions

1.2.5 Escape routes, safety facilities

1.2.6 Attendance and operation of the plant unit

1.2.6.1 Personnel qualification

Version 01-2011 General safety information

sequences of open- and closed-loop control, the operating parameters

1.2.6.2 Measures before and after start-up of the plant unit

1.2.7 Malfunctions, damage, service and maintenance

1.2.7.1 Elimination of malfunctions and correction of

1.2.7.2 Personnel qualification

1.2.7.3 Measures prior to start of service and maintenance

General safety information Version 01-2011

1|4-4 © MAN Diesel & Turbo SE TGS_ O32410018

1.2.7.4 Fire and explosion hazard

1.2.7.5 Work on piping

1.2.8 Work on electrical systems

Version 01-2011 General safety information

1.2.9 Access to the noise control enclosure or the machine

1.2.10 Fire and explosion hazard

1.2.11 Fire alarm, discharge of fire extinguishing gas

1.2.12 Personal protective equipment

1.2.13 Spare parts, modifications to the scope of supply

General safety information Version 01-2011

1|6-6 © MAN Diesel & Turbo SE TGS_ O32410018

Version 01-2011 General safety information

2.2 Marking of component parts

2.3 Pressure data

Version 01-2011 Introduction

Materials receiving Monday to Friday from 06.00 to 13.00 hours

Introduction Version 01-2011