Clutch Company, Inc. Starting System Upgrade for General Electric Frame MS-6001 Gas Turbine Generators

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August Gilbert Osborne
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1 Starting System Upgrade for General Electric Frame MS-6001 Gas Turbine Generators SSS Clutch Company, Inc. June 12, 2007 New Castle, Delaware Clutch Company, Inc.

2 SSS Clutch Company, Inc. & SSS Gears Limited SSS - The Companies Engineering and Application based Small => focused on solutions, quality & minimum bureaucracy Subcontract component manufacturing with strong control 100% Responsible 100% Design 100% Assembly 100% Test. SSS - The Product Fit and forget Highly engineered custom design product Unique - used in critical applications. 2 sssgears.co.uk

3 SSS CLUTCHES - MAIN APPLICATIONS: 1. Marine systems - main propulsion: Naval Vessels & Fast Ferries. 2. Process systems: Fans, Pumps, Compressors etc. 3. Power Generation systems: Gas & Steam Turbine Generators 4 Auxiliary systems: Starting and turning systems 3 sssgears.co.uk

4 GE Frame MS-6001 Gas Turbine Generator 4 sssgears.co.uk

5 History Change to SSS Size 64T Clutches Initiated by Gas Turbine End Users Over 7500 Jaw Clutches installed on starting and turning gear drives on GE Turbines (Earl Beemis, GE, Schenectady circa 1990) 1990 Kansas Power & Light, Tecumseh purchased the first Two 64T s for Frame 5 s 1991 Consolidated Edison purchased the First 2 of 48 64T s for Frame 5 s in Narrows and Gowanus Power Stations, Brooklyn, NY GE purchased the first 64T for a test cell in Greenville, SC assembly facility 1993 GE purchases the first two 64T s for the Frame 6B for Atarot Power Station, Israel Electric Company clutches installed on Frame 6B s 610 clutches installed on Frame 5 s 10 clutches installed on Frame 7B s 5 sssgears.co.uk

6 GE Model A-500 A Accessory Gearbox used on MS-6001 Gas Turbine with Starting Jaw Clutch on Input of Number 1 Shaft 6 sssgears.co.uk

7 Detail of Jaw Clutch with Two Horizontally Positioned Air Cylinders for Engagement and Disengagement Engaged Position Disengaged Position 7 sssgears.co.uk

8 Jaw Clutches Potential Problems Jaw Clutch May not slide on the torque converter shaft splines due to wear, dirt, rust, etc. Jaw Clutch does not engage properly due to wear or only partially engages teeth and subsequently is damaged on start. 8 sssgears.co.uk

9 Jaw Clutches - Potential Problems Limit switch is grounded, open, or has moved out of position due to vibration or clutch hang-up preventing Gas Turbine start. Jaw clutch does not engage because the actuation pistons are leaking (not holding) or have sheared off due to misalignment. 9 sssgears.co.uk

10 Approximate Deceleration Time for Frame 6001 Gas Turbine Generator and Speed where Re-Start can be Initiated Jaw clutch does not disengage and start must be aborted. If gas turbine startup is aborted (loss of flame, vibration trip, high exhaust temperature, etc.), unit can not be restarted with jaw clutch until the gas turbine rotor comes to zero rpm. Turbine Windmilling and can not re-start 10 sssgears.co.uk

11 Page 24 of GE Paper on Improvements for the MS 5001 Gas Turbine - Retrofit of SSS Clutch for GE Starters - Frame 3, 5, 6, or 7B GE Standard New and Retrofit 11 sssgears.co.uk

Benefits of Installing a Size 64T SSS Clutch - the Following Items can be Eliminated: The jaw clutch and its associated guard. Actuating cylinders used to engage the jaw clutch.

12 Benefits of Installing a Size 64T SSS Clutch - the Following Items can be Eliminated: The jaw clutch and its associated guard. Actuating cylinders used to engage the jaw clutch. The two-position, four-way valve used for cylinder actuation. Switches to prevent diesel start unless the jaw clutch is engaged. Zero-speed sensor and interlock. Pneumatics or hydraulics from Starting System Skid (Com Ed). Frame 5 Jaw Clutch at NRG, Arthur Kill Station, Staten Island, NY 12 sssgears.co.uk

Benefits of Installing Size 64T SSS (Synchronous Self- shifting) Clutch in Starting Drive of MS-6001: Improvement in gas turbine generator starting reliability Reduced annual preventative maintenance

13 Benefits of Installing Size 64T SSS (Synchronous Self- shifting) Clutch in Starting Drive of MS-6001: Improvement in gas turbine generator starting reliability Reduced annual preventative maintenance efforts and cost. Reduction in trouble-shooting and corrective action efforts. Capability to reduce time needed to respond to quick start in the event a first attempted start is aborted (Consolidated Edison, NY). Installation on GE Frame 5 at NRG, Gowanus Station, Brooklyn, NY 13 sssgears.co.uk

Size 64T SSS Clutch Design Features Clutch engaging teeth large backlash to improve misalignment capability (Note: Good initial alignment and dowels still important for driving and driven

(Frame 3, 5 or 6) Size 64T fits existing space between torque converter and accessory gear regardless of DSBE (1.312 inch or.533 inch are GE standards).

14 Size 64T SSS Clutch Design Features Clutch engaging teeth large backlash to improve misalignment capability (Note: Good initial alignment and dowels still important for driving and driven machinery). Clutch casing - cast aluminum to reduce cost and reduce weight. Clutch designed for GE accessory gear shaft or torque converter output shaft with straight splines or keyway. (Frame 3, 5 or 6) Size 64T fits existing space between torque converter and accessory gear regardless of DSBE (1.312 inch or.533 inch are GE standards). Clutch output component has six equally spaced radial holes for machinery alignment check with depth micrometer. Machinery angular alignment can be measured between clutch casing and torque converter housing in four places. 14 sssgears.co.uk

15 Mark V & VI Control System (Programmable) Alterations Additional Speed Tronic control card to give signal when the GT is at or below 500 rpm. Modification to permissive circuit to allow a re-start at up to 500 rpm. Provision for automatic quick start mode to eliminate 3-minute warm-up cycle for the diesel (Con Ed). Circuit wiring for clutch start solenoid (CS Control Wire No. 20 in Mark I) is removed. Zero speed sensor (Control Wire 14-HR in Mark I) is eliminated. The clutch starting circuit (CS Control Wire No. 30 n Mark I) is reallocated for a limit switch for new 64T clutch to signal when clutch is engaged and disengaged. Signals so the diesel can be shut down. Mark I Speed Tronic Control panel with 500 rpm manual re-start switch at NRG, Gowanus Station, Brooklyn, NY 15 sssgears.co.uk

16 Most Common Configuration of Size 64T for MS-6001 Starting System (SSS Drawing SL 17737) 16 sssgears.co.uk

17 The SSS Clutch How Does It Work? Condition with output at high speed 17 sssgears.co.uk

18 Data Required to Determine Correct 64T Configuration 1) Turbine Frame Size and Model 2) Driven Machine Generator Compressor Other: 3) Type of Starting: Electric Motor Diesel Steam Turbine Expander Other: 4) Model of Torque Converter (if used): Allison Twin Disc Voith Serial No. 5) Direction of rotation of the clutch looking from the starting motor to the gas turbine: Clockwise Counter-Clockwise 6) Distance between torque converter and accessory gear shaft ends (or starting turbine and accessory gear):.533 inches inches Other: 7) Is torque converter output shaft keyed or splined: a) Keyed: Diameter Key Size b) Splined: Diameter No. of Splines 8) Is accessory gear input shaft keyed or splined: a) Keyed: Diameter Key Size b) Splined: Diameter No. of Splines 9) Accessory Gear Model and Serial Number: 18 sssgears.co.uk

19 Interfaces, Installation Time, and Approximate Cost Starting System Interface Requirements for 64T SSS Clutch Oil Supply Line 1/4 NPT Connection on SSS Casing (3/8 pipe) Drain Line Connection 1 ½ NPT Connection on SSS Casing Electrical Connection 12 or 24 VDC or 110 or 220 VAC for SSS Proximity Switch Installation Time and Approximate Cost Cost of System Retrofit Approximately $20,000 for Hardware Time to Retrofit 64T About 5 days using two people (Clutch only is about 2 days) 19 sssgears.co.uk

Steps to Install - Size 64T SSS Starting Clutch for GE Frame MS-6001 Gas Turbine Generator Torque converter output (left) shown with torque converter

20 Steps to Install - Size 64T SSS Starting Clutch for GE Frame MS-6001 Gas Turbine Generator Torque converter output (left) shown with torque converter rolled into vertical position and jaw clutch removed. Accessory Gearbox input (right) prior to removal of Adaptor Ring and Labyrinth Seal. 20 sssgears.co.uk

21 Installation of size 64T SSS Clutch in MS-6001 Starting System Installation of SSS Clutch Input Hub on Torque Converter Output Shaft TIR. 21 sssgears.co.uk

22 Installation of size 64T SSS Clutch in MS 6001 Starting System Labyrinth Seal Removed from Accessory Gear Shaft and Replaced with SSS Housing Adaptor Plate Installation of SSS Housing Adaptor to Accessory Gear TIR. 22 sssgears.co.uk

23 Installation of size 64T SSS Clutch in MS-6001 Starting System Accessory Gear shaft after installation of clutch output sleeve and housing adaptor SSS Clutch Output Sleeve installed on Accessory Gear Shaft Maximum.002 TIR. 23 sssgears.co.uk

24 Installation of size 64T SSS Clutch in MS-6001 Starting System Input Assembly Installed and Lower Casing Installed 24 sssgears.co.uk

assemblies shown in final positioning in between

and accessory gear Connection of Rigid Half

25 Installation of size 64T SSS Clutch in MS-6001 Starting System Size 64T SSS Starting Clutch half assemblies shown in final positioning in between motor (or diesel engine) driven torque converter and accessory gear Connection of Rigid Half Coupling to Clutch Output Clutch Ring. 25 sssgears.co.uk

26 Installation of size 64T SSS Clutch in MS 6001 Starting System Maximum Variation of.004 in Six Places. 26 sssgears.co.uk

27 Installation of size 64T SSS Clutch in MS 6001 Starting System Axial Measurement of Sliding Component to SSS Housing Adaptor in Two Places. Difference should be 1/8 plus or minus 1/ sssgears.co.uk

28 Installation of size 64T SSS Clutch in MS 6001 Starting System Install Lower Housing, Two Floating Oil Seals, & Proximity Switch (not shown). 28 sssgears.co.uk

29 Installation of size 64T SSS Clutch in MS 6001 Starting System, Hastings, NE Installation of Top Half of SSS Clutch Housing. Oil Supply Line Connected to Top of Accessory Gear Adaptor Plate for Size 64T SSS Clutch Casing. 29 sssgears.co.uk

30 Drain Pipe Connection from Bottom of Size 64T SSS Clutch to top of MS-6001 Gas Turbine Accessory Base Oil Tank 30 sssgears.co.uk

31 Oil Supply Line Connection for Size 64T SSS Clutch, Hastings, NE 31 sssgears.co.uk

32 Size 64T Retrofitted into MS-6001 Starting System at CFE, Los Cabos,, Mexico 32 sssgears.co.uk

33 Size 64T SSS Clutch Orders for G.E. Frame 6 Gas Turbine Starting Drives 33 sssgears.co.uk

34 Size 64T SSS Clutch Orders for G.E. Frame 6 Gas Turbine Starting Drives 34 sssgears.co.uk

35 Size 64T SSS Clutch Orders for G.E. Frame 6 Gas Turbine Starting Drives 35 sssgears.co.uk

36 Companies Who have Installed or Retrofitted Size 64T SSS Clutches General Electric, Greenville, SC General Electric CM & U, Atlanta, GA General Electric, Belfort, France Nuovo Pignone Corporation Hitachi Pond & Lucier Rotating Parts & Maintenance (RPM) Wood Group Turbine Technology Services Sermatech Power Engineering Services and Solutions (PESS) Mechanical Dynamics & Analysis (MDA) 36 sssgears.co.uk

37 Thank You Clutch Company, Inc.

HFP Series. Specifications. Switch specifications. Wide parallel hand Double acting. Operational stroke length: 20, 30, 40, 60mm.

HFP Series. Specifications. Switch specifications. Wide parallel hand Double acting. Operational stroke length: 20, 30, 40, 60mm. FH0 G B FH0 G A S F J H2 N/ S/F Specifications Size Cylinder bore size mm Actuation Working fluid Max. working pressure MPa Min. working pressure MPa Ambient temperature C Port size Operational stroke