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LCGT is a small cogeneration
system catering to power levels of 300 –
500 Kwe with gaseous or liquid fuel. It is
a single stage expander with a single stage
compressor used in place of any existing heat
generator. Fuel used in the heat generator
is fed to the LCGT, thus converting heat energy
(of fuel ) to electrical power. The governor
of the LCGT regulates the fuel flow rate so
as to maintain the requisite speed of the
alternator. Fuel is thus used twice, first
for power generation and then for process
heating.
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Uses of LCGT |
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LCGT
can be used by several process industries like
Distilleries, Chemicals, Pharma, Paper, Food
or any industry where there is a requirement
of both heat and power. LCGT can also be used
in hospitality industry where outlet from the
LCGT can be used to generate chilled water for
air conditioning. |
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LCGT handle liquid and
gaseous fuel
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This
is made possible by use of advanced technology
and superior materials of construction and incorporating
latest control philosophy for multi-fuel usage. |
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Turbine
is coupled to an alternator through a two stage
speed reduction epicyclic gearbox. The LCGT
package comes complete with electrical panel
and terminal connections in a single skid..
This simplifies the electrical connectivity
to any nearby Power control centre of adequate
rating and capacities. |
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Savings and payback on
investment
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Power thus generated will
be anywhere between $0.10 to $0.30 per unit based
on the fuel used. Payback is usually within a
year. LCGT qualifies for 100% depreciation in
the first year itself. Further LCGT helps in reducing
CO2 emission by saving precious fossil fuel burnt
in power plant. |
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People behind LCGT |
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TurboTech precision Engineering
(P) Ltd is spearheaded by a team of highly qualified
engineers trained in Gas Turbines used for Aero
engines. Thus TurboTech brings Aerospace technology
to Gas Turbine manufacturing, giving a World class,
highly efficient product at Indian Prices. |
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Product Range |
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TurboTech has developed only
a 500 Kwe Gas turbine with option to use any gaseous
or liquid fuel having a clorific value of 4500
kcal/kg or more and having low sulphur content.
Our specialty is in making versatile turbines
to suit exact customer requirement. TurboTech
also offers steam turbines for steam users upto
2.00 MW |
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Summary of Proposal Client:
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500 KW low cost gas turbine
consisting of : |
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Gas Turbine. |
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20:1 2-stage reduction Gear Box. |
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Induction Generator 625 KW/ 415 V. |
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Skid with Pressurized Lube Oil system. |
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Electrical Power Panel. |
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Requisite instrumentation and control
panel. |
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Technical Description of
Gas Turbine Turbo-Generator set |
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The plant consists of the
following major items: |
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500 kWe Gas Turbine Generator
set with fuel control system |
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Electrical control Panel |
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Instrumentation panel for controls |
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Brief Description of the plant |
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500 kWe Gas Turbine Generator
set. |
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This consists of a single
stage radial in-flow turbine and a single stage
centrifugal compressor mounted on a common shaft
running at 30,000 RPM. It has a single can reverse
flow combustor fitted with a multi-fuel injector.
The turbine shaft speed is reduced to 1500 RPM
through a 20:1 two stage epi-cyclic gearbox. In
addition the turbine is fitted with a closed circuit
lubrication system. The PLC based control system
carries out the pre-start checks, starts the turbine
and ensures ‘fail safe’ shut-down
of the system in the event of any undesirable
operating condition.
The designed pressure ratio and mass flow will
deliver 500 kW net electrical power under standard
ambient conditions (at Sea level and 30oC). The
gas turbine system has been designed to address
the power and heat requirements of certain industry
segments, i.e. 500 kWe of power and approximately
2.5mkCal/hr in the exhaust stream, aimed at a
high cogen efficiency of 85%.
The entire system is assembled on a single skid
incorporating the gear box and the complete lube
system and the fuel control system. The control
panel is separately housed in a IP23 enclosure
so as to mount it at any convenient location near
the turbine. The single skid system is equipped
with a convenient lifting tackle points to enable
quick and easy positioning at site. |
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Gear Box |
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The gear box comprises two
Co- axial epicyclic trains in a star planetary
series arrangement. The primary star stage has
three star wheels meshing with the sun wheel input
member mounted directly on the engine shaft which
rotates at 30,000 RPM. The associated annulus
is directly coupled to the secondary planetary
Sun wheel such that the assembly so formed is
fully floating on the planet wheels whose planet
carrier is mounted on the output shaft. The gear
trains have been so designed that the primary
star wheels have exactly the same tooth numbers
and geometry planet wheels. The primary star carrier
and the secondary annulus are therefore fixed
to the gear case to serve collectively as the
fixed reaction member |
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Alternator |
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The alternator is driven from
the gearbox using a flexible coupling. The alternator
is of the 4-pole type, with external fan cooling.
500 KW, IP-21 Class, 4160V, 3 phase, 60Hz. alternator
and other accessories as specified in annexure.
II |
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Skid with Pressurized Lube Oil system |
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MS fabricated common skid
for Turbine, gearbox, generator, and lubrication
system fitted with anti-vibration pads. |
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Electrical panels |
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4160 V Breaker Power panel
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Metering/ protection relay
panel |
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Detailed specifications of 500 kWe
Gas Turbine Alternator
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| Type : |
Single shaft, constant speed
(30000 rpm) |
| Rating : |
500 kWe, continuous at 30oC ambient, Sea
level |
| Compressor
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Single stage, 4:1 pr. Ratio, 17-4 PH stainless
steel rotor, mass flow 4.4 kg/s |
| Turbine : |
Single stage radial in-flow, Inconel 738
rotor. |
| Combustor : |
Single can (Nimonic75 alloy), reverse
flow with multi-fuel injector. |
| Gearbox : |
20:1, two-stage epi-cyclic gearbox, output
1500RPM |
| Bearings : |
Babbitt on steel, multi-lobe, journal
cum thrust |
| Lubrication : |
Closed circuit oil pressure system to
all bearings and gears. |
| Controls : |
PLC based start and control system. |
| Fuels : |
Multi-fuel capability. |
Gaseous
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Biogas, LPG, Natural gas, any clean gas
of calorific value>4500 kCal/NM3 |
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Kerosene, Diesel, ATF, any light distillate
< 0.3% Sulfur. |
| Typical fuel
consumption : |
340L/hr of SKO/334Nm^3/hr Natural gas/
250kg/hr of LPG/ 700NM3/hr of Biogas at
full load. |
Fail-safe
protection against: |
High exhaust temperature
Low lube oil pressure
High lube oil/ bearing temperature
Over speed
Over load
Abnormal voltage, vibrations etc.,
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Materials of construction & features
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Compressor wheel |
CNC
machined integrally bladed disc, from 17-4
PH precipitati hardened stainless steel
forging |
| Turbine wheel |
Vacuum Investment
Casted Inconel alloy wheel precision ground
and machined. |
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Nozzles and guide vanes |
high temperature
resistant alloy CNC milled |
| Turbine housings
and all as wetted critical parts |
High Temperature
alloy castings |
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Turbine shafting |
IN 738 forging |
| Gears |
Hardened steel
gears ground to DIN Class 5 for low noise
operation and minimum transmission loss. |
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Bearings |
Babbitt on steel
journal bearings with proprietary design
multi-lobes for optimal hydrodynamic loading. |
| Seals |
Specially engineered
stainless steel Laby seals |
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Alternator-Annexure II
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Brief
Description |
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500
KWe, 415V, 3-Phase, 1500 RPM, 50Hz, horizontal
shaft, foot mounted, single shaft extension, double
bearing alternator suitable for ambient of 45°C,
with IP:21/IC:01 enclosure, Class F insulation
and temperature rise limited to class F, confirming
to IS-4722. alternator suitable for voltage regulation
+/-1. alternator terminals will be on LHS of the
alternator. |
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Specifications |
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Make |
Siemens/any
reputed manufacturer |
| Construction |
Horizontal shaft,
Double bearings, Foot mounted. |
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Rating |
500 KW |
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Rated power factor |
0.8 lag |
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Voltage |
415V +/-10% |
| Frequency |
50Hz +/-3% |
| No.
of phases |
3 |
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No. of poles |
4 |
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Insulation |
Class F |
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Temperature rise for both rotor & stator |
Limited to class
F(105oC by resistance method) |
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Ambient |
45oC |
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Duty |
S1 (continuous
operation) |
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Drive |
Gas turbine |
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Rotation |
Counter Clockwise
from drive end of generator |
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Phase sequence |
UVW |
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Type of excitation |
grid excitation. |
Enclosure / cooling-Generator
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IP-21/IC-01 |
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Efficiency - at 100% load |
94% |
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Over speed |
Suitable for
120% rated speed for 2 minutes. |
| Over
load |
Suitable for
10% overload for 1hr every 12 hours |
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Momentary overload |
150% for 15
seconds |
| Short
circuit with stand ability |
3 times rated
current for 3 seconds |
Wave
form distortion factor at no load between
lines
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Less than 5% |
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Bearings |
Qty. |
2 Nos. |
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Type |
Anti-friction
ball / roller |
| Lubrication |
Grease lubricated |
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Accessories fitted |
Anti condensation
heaters and 6 nos. RTD’s. |
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SCOPE OF SUPPLY
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The
following items/constituents will comprise of
the total scope of supply to be delivered to the
customer: |
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Low Cost Gas Turbine with
Single stage expander, single stage compressor
and silo type combustor |
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Gear box consisting of two stage 20:1
reduction, epicyclic gear box mounted on
the high speed shaft of the gas turbine. |
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Bearings with babbit on steel journal
and thrust |
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Custom designed multi-stage labyrinth
seals |
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Coupling which is flexible transmission
tube type coupling between gearbox and generator |
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Lubrication system with closed circuit
pressurized lubrication to all bearings
and gears. Mechanically driven main oil
pump and electrically driven pre-lube, post
lube and standby pump |
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Single skid for turbine, generator, lube
system, coupling and other accessories. |
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Control system, which is PLC based, with
I/O modules for health monitoring and ‘fail-safe’
trip. |
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Control Cum Shut-off fuel system for accurately
controlling and maintaining speed of the
turbine and generator and for quick-shut
off in case of turbine trip. |
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Power panel incorporating ACB for electrical
controls with other safeties |
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OPTIONAL ITEMS
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Vibration switch for high
vibration trip. |
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Sound enclosure for maintaining sound
level to 92 dBA at 1 mt. |
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40 hour full load test. |
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List Of Exclusions: |
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Following
are excluded from TurboTech’s scope of supply
and scope of work. These are to be carried out
by client at his cost. |
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All statutory clearances. |
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All civil works including foundation
for machinery |
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5 MT OHT/A-frame crane in turbine room. |
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All piping for exhaust hot gases. |
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Compete fuel system including fuel inlet
piping to the turbine with fuel booster
pumps or compressor. |
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Cooling water supply and return piping
for oil cooler |
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Water measuring instruments |
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Cooling towers, cooling water circulation
pump and related piping work. |
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Instrumentation air supply and air piping |
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All field instrument cabling. |
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All power cabling. |
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Power evacuation from generator breaker
panel. |
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Earthing for all equipments |
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