Lloyd s Register Type Approval System Test Specification Number GT04 Gas Turbines Performance and test specifications for Gas Turbines to be used in Marine, Offshore and Industrial Applications 2004
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Foreword This Specification details the documentation, performance and tests required for the Lloyd's Register (LR) Approval of gas turbines for Marine, Offshore and Industrial applications. This test specification should be read in conjunction with the LR Type Approval System - Procedure TA02. Failure to comply with this requirement may render the test results unacceptable for the purposes of LR Type Approval. 1 Reference:
Table of Contents 1. Introduction... 3 2. General... 3 2.2. Phase 1... 3 2.3. Phase 2... 3 3. Details of Required Documentation... 4 4. Testing Procedures... 5 5. Visual Inspection and Certification... 6 6. Production Inspection and Certification Phase 3... 6 6.1 General... 6 6.2 Construction under Survey... 6 6.3 Alternative Quality Scheme of Inspection... 6 2 Reference:
1. Introduction 1.1. This specification is intended as an aid to assist a Producer seeking LR Type Approval of gas turbines for use in Marine, Offshore and Industrial applications and should be read in conjunction with the LR Type Approval System - Procedure TA02.` 1.2. Type Approval of gas turbines containing electrical and control components will be based on agreed performance and environmental tests. Assessment of Safety Systems fitted to such units will be carried out. 1.3. Electrical and control components may be required to meet the requirements of the LR Type Approval System - Test Specification No. 1. 1.4. Separate Type Approval certificates are not issued for individual components on the basis of tests carried out on a composite product. 2. General 2.1. The Type Approval will be considered in three phases. During the Phase 1 review of the documentation and an appraisal of the design will be completed. The Type Testing and the issue of the appropriate certification will be carried out in the Phase 2. Phase 3 consists of the production inspection and certification. 2.2. Phase 1 2.2.1. The submitted information will be forwarded by the Local LR office to the Type Approval Centre for consideration. 2.2.2. A document review will be conducted to determine such facts as product acceptability, compliance with relevant standards and LR s Rules, design appraisal, adequacy of proposed Type Test programme and relevance of previous certification and reports. 2.3. Phase 2 2.3.1. Type Tests shall be carried out in accordance with the agreed test programme on a representative machine, to confirm that the performance provisions of the specified standard(s) are fulfilled. Type Tests are to be witnessed by the local LR representative, unless otherwise agreed in writing. 2.3.2. All test and measuring equipment shall be of proven accuracy, where appropriate traceable to a National or International standard of measurement. 2.3.3. Test area ambient conditions are to be monitored throughout testing. 2.3.4. Type Tests may be carried out at the manufacturer s works or at any establishment having suitable facilities acceptable to LR. 2.3.5. On completion of tests, a report shall be issued, identified by number and date, which accurately, clearly and unambiguously presents the test results and all other relevant information. The English language should be used. 2.3.6. Test reports shall be signed by the test personnel and countersigned, as verification of the results, by the LR or agreed independent representative witnessing the tests. 2.3.7. When the machine has been deemed to satisfy the procedures for LR Type Approval, a Type Approval Certificate will be authorised. 3 Reference:
3. Details of Required Documentation 3.1. Submission in triplicate of the following: 3.1.1. Request for LR Type Approval via thelocal office, 3.1.2. Detailed product specification, 3.1.3. Relevant design drawings with materials specified, catalogues, data sheets, calculations and functional descriptions, 3.1.4. Full details of: 3.1.4.1. Sectional assembly drawing, 3.1.4.2. Combustion chambers and heat exchangers, 3.1.4.3. Rotors, bearings and couplings, 3.1.4.4. Blades and blade attachments, 3.1.4.5. Inlet and exhaust ducting, 3.1.4.6. Securing arrangements, including details of resilient mounts where applicable, 3.1.4.7. Control systems schematics, 3.1.4.8. Fuel oil schematic, including controls and safety devices, 3.1.4.9. Lubricating oil system schematic, 3.1.4.10. Starting system schematic, 3.1.4.11. Cooling water system schematic, where applicable. 3.1.4.12. Calculations of the critical speeds of blade and rotor vibration, giving full details of the basic assumptions. 3.1.4.13. Calculations concerning the amplitude and frequency of vibration associated with any resilient type mountings 3.1.5. Proposed field of application and operational limitations. 3.1.6. Proposed Type Test programme, sufficiently detailed in order to demonstrate that the performance provisions of the specified standards may be fulfilled for acceptance, 3.1.7. Certificates and reports for relevant tests previously obtained for the machine, 3.1.8. Copies of the relevant standards where necessary. 4 Reference:
4. Testing Procedures 4.1. Generally, the requirements of BS 3135:1989 (ISO 2314:1989) will be used for the basis of the Test programme. The primary objective of the tests is to determine: 4.1.1. Power output under specified operating conditions against ambient temperature (gas power, if only a gas generator is supplied), 4.1.2. Thermal efficiency, heat rate or specific fuel consumption under specified operating conditions and, 4.1.3. The adequacy of essential protective devices (i.e. emergency overspeed trip and flame failure trip, if installed). 4.2. Additional tests to those detailed in 4.1 above, are: 4.2.1. Performance of the following governing and protective systems; 4.2.1.1. Constant speed regulation, 4.2.1.2. Variable speed regulation, 4.2.1.3. The gas turbine temperature control, gas turbine exhaust, turbine inlet or other limiting temperatures as applicable 4.2.1.4. Low lubricating oil pressure, 4.2.1.5. High lubricating oil temperature, 4.2.1.6. High bearing temperature, 4.2.1.7. Fuel supply pressure and, 4.2.2. Handling characteristics, for example; 4.2.2.1. Starting sequence, 4.2.2.2. Starting reliability, 4.2.3. Special starting characteristics, such as - black start, remote start, emergency start, dead load pick-up, alternative fuel start on dual fuel machines, starting power requirements, minimum self-sustaining speed determination and starting fuel consumption, 4.2.4. Normal load pick-up, 4.2.5. Time period for start-up and loading. 4.2.6. Amplitude and frequency of rotor vibration. 4.2.7. Amplitude and frequency of vibration associated with any resilient type mountings, (see 3.1.4.13 above). 4.2.8. Stack emissions, in accordance with a recognised test method, 4.2.9. Exhaust mass flow and temperature (for waste heat recovery evaluation), 4.2.10. Noise levels (generally in accordance with ISO 10494:1993), 4.2.11. Dependent upon the field of application of the gas turbine, additional special testing may be required. This may include operating in excess of the maximum continuous rating and inclination tests. 5 Reference:
5. Visual Inspection and Certification 5.1. Following successful completion of Design Appraisal and Type Testing, the manufacturing facilities will be inspected to ensure that the appropriate procedures are in place in order to maintain conformity of manufacture for the five year life of the Type Approval Certificate. 5.2. Only when all outstanding points have been mutually resolved will the Type Approval Certificate be authorised and issued. 6. Production Inspection and Certification Phase 3 6.1 General 6.1.1. Type Approved gas turbines intended to be fitted into LR classed ships are to be surveyed at the manufacturer s works during their production. 6.1.2. The manufacturer has a choice of two production inspection and testing procedures. 6.2 Construction under Survey 6.2.1. Individual gas turbine units are to be surveyed at the manufacturer s works. The Surveyors are to examine and test the materials and workmanship from the commencement of work until the final test of the gas turbine under full power working conditions in accordance with the rules. 6.3 Alternative Quality Scheme of Inspection 6.3.1. Where gas turbines are manufactured as individual or series produced units a survey procedure based on quality assurance concepts utilising regular and systematic audits of the approved manufacturing and quality control processes and procedures as an alternative to the direct survey of individual items. 6.3.2. The procedure is detailed in LR Rules for Classification of Ships, Part 5, Chapter 1, Quality Assurance Scheme for Machinery. 6 Reference:
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