ORION-5000

5.2 mw

Turbine Technology

Powering the Future

Section 1 Scope of Offering

Section 2 Pictures of ORION 5000

Section 3 Technical Description

Section 4 Power Control Room (PCR) Building

Section 5 Performance

Section 6 Emissions

SECTION - 1

SCOPE OF EQUIPMENT OFFERING

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

This offer includes for each turbine:

• Enclosed - Skid Mounted or Mobile ORION 5000 units. The trailer deck with wheels is not included in the price on the skid mounted units. It can be purchased as an option.

• Single fuel only (natural gas) – Mobile Units.

• Dual fuel (natural gas/No. 2 diesel) – Skid Mounted Units.

• SoLoNOx dry low-NOx combustion system.

• Each ORION 5000 turbine generator package is capable of producing a nominal 5,200 kW at 13,800 volts in peaking service.

• All associated turbine inlet and exhaust systems.

• Each unit comes equipped with a Power Control Room (PCR) Building and the associated ancillary equipment.

• Skid mounted units are new with zero runtime hours each.

• Mobile units are essentially new with approximately 10 to 12 runtime hours each. The units have not been in commercial operation. Runtime hours have been for testing and commissioning.

• Current Equipment Warranties are included. Extended warranties are available depending upon the purchaser’s application.

SECTION - 2

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

ORION 5000 5.2 mw – Mobile

Single Fuel (Natural Gas)

ORION 5000 5.2 mw – Skid Mounted

Dual Fuel (Natural Gas & #2 Diesel)

SECTION - 3

TECHNICAL DESCRIPTION

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

I. BASIC PACKAGE

The Orion 5000 Industrial Power Generator is a compact, rugged gas turbine generator set that has been designed to meet the requirements for industrial power generation applications. The unit is provided as a completely integrated module ready for installation. The gas turbine engine, gearbox, generator, control system, fuel system, lubrication system, start system, and ancillary equipment are included in the package.

Features included in this offering are:

Base. The base provides structural support for the Orion 5000 gas turbine engine, gear box, generator, enclosure, and all operating systems. The base is manufactured by Orion using structural steel with welds per AWS D1.1. Approximate overall dimensions are:

32 feet, 0 inches (9753 mm) long

8 feet, 0 inches (2438 mm) wide

Approximate height of package is 10 feet, 8 1/4 inches (3258 mm) and may vary with ancillary equipment and generator selection. Four lifting gussets are provided on each section.

Drip pans are welded beneath the package frame to collect potential liquid spills. The drip pans also provide a tight seal for containment of fire suppression agent for packages supplied with an enclosure.

Tube Fittings. All tube connections use compression fittings. Tubing and fittings are 316 stainless steel.

Piping. Package piping is designed and fabricated to ANSI B31.3.

Electrical System. The Orion 5000 IPG generator set is designed to comply with the requirements of the National Electrical Code and is intended to be installed in a non hazardous location per the NEC.

Unless otherwise noted package motors and heaters are rated for 460 VAC, 60 Hertz, 3 phase. Motor space heaters are provided for motors over 5 hp (3.75 kW) and are rated for 120 VAC, 60 Hertz, 1 phase. Except where indicated, connectors and motor starters are not included.

Fire Detection and Suppression System. The gas turbine enclosure will be provided with ultra violet fire detectors and fire monitoring system. The fire suppression system agent is CO2. In the event of a fire being detected within the unit, the unit will shutdown, the enclosure ventilator louvers will close, and horns will sound.

Gas Detection System. Gas detection monitors are provided in the turbine enclosure. Upon detection of 20% LEL, alarms will sound. Upon detection of 75% LEL, the unit will shut down and all louvers will open, and all ventilator fans will activate.

II. GAS TURBINE ENGINE

The Orion 5000 gas turbine engine is a single shaft axial flow engine. The output gearbox, including accessory drive pads, is a separate, close-coupled unit located at the inlet end of the turbine.

The engine assembly consists of:

• Gear unit with accessory drive pads

• Air inlet collector with flexible flange connection

• Axially split case in the vertical plane, eleven-stage axial flow compressor with variable temperatures.

• Geometry control on inlet guide vanes and first two rows of stators

• Annular NOx combustor with 12 lean premix fuel injectors

• Three-stage turbine assembly

• Turbine exhaust collector

The components of the Orion 5000 engine are maintained in accurate alignment by mating flanges with pilot surfaces and are bolted together to form a rigid assembly. The speed reducing gearbox is driven by the compressor rotor shaft. Accessory pads drive the main lube oil pump and other accessories, depending on the application, and supports the starter motor.

The gas turbine output shaft is mechanically connected to both the compressor and turbine sections of the engine to form a "solid" or "single" shaft configuration. This feature enhances speed stability and response under constant and varying load conditions – a highly desirable feature in generator applications requiring precise frequency control.

A turbine engine cleaning system is provided. The system includes nozzles installed in the air inlet housing and on skid piping and controls. The cleaning system is designed for operation while the engine is cranked by the start motor.

III. SPEED REDUCING GEARBOX

The speed-reducing gearbox is an epicyclic star-gear industrial design manufactured by Orion specifically for the Orion 5000 IPG generator set. The gearbox mounts directly on the Orion gas turbine to reduce engine speed to 1800 rpm (60 Hz).

IV. GENERATOR

Generator Rating. Generator nameplate rating per NEMA standards is 6,625 kVA at 0.8 power factor (5,300kW) at 104oF (40oC), 3281 ft (1000 m) elevation for continuous duty. The generator is rated so that the generator will not limit turbine performance over the range of site ambient temperatures.

Generator Standard Features

• Sleeve Bearings with pressure fed sumps

• Six-lead WYE connection

• Terminal box

• Form wound stator windings

• Damper windings

• Rotor balance to 125% rated speed

• Permanent magnet pilot exciter

• Anti-condensation space heaters

• 300% short circuit capability for 10 seconds

• Overload capacity per NEMA:

• 150% rated current for 1 minute

• 110% for 2 hours

Voltage Regulator Characteristics

• Solid state

• Single-phase sensing

• ±10% voltage adjustment range

• 0.5% steady state voltage regulation

• Reactive load sharing to within 5% nameplate rating

• Crosscurrent compensation capability

Wave Form Characteristics

• Deviation Factor [maximum] 6%

• Harmonic Content [maximum] 3%

• Telephone Interference Factor 50

• Balanced Residual 75

Voltage Drift. The change in voltage will not exceed 1.0% over a 30-minute period when the generator is operating at rated voltage and 0.8 to 1.0 power factor and with a constant load between no load and full rated load.

Generator Voltage. The generator output is 13,800 Volt, 3 phase, 60 Hz. Insulation conforms to NEMA class F with class F (105Co) temperature rise.

V. TURBINE START SYSTEM

A direct drive AC motor is provided to start the Orion engine. A variable frequency drive [VFD] motor controller is included for installation in the motor control center [MCC]. 3 phase AC power is required at 380-415VAC, 50Hz/460VAC, 60Hz, 250 Amperes. The control system provides all required sequencing to quickly and reliably start the turbine.

VI. FUEL SYSTEM

The fuel system, in conjunction with the electrical control system, includes all necessary components to control the fuel pressure, to schedule fuel flow during start-up, and to modulate fuel flow during operation.

Natural Gas Fuel. A natural gas fuel system is provided with all components necessary to maintain turbine speed to provide a constant generator output frequency and/or load depending on the generator set mode of operation. Orion's Specification ES 9-98 contains the specific fuel requirements.

The natural gas fuel system includes:

• Primary fuel shutoff valve

• Pilot-operated secondary fuel shutoff valve

• Electronic fuel actuator

• 10-micron pilot gas filter

• 12 fuel injector assemblies

• Valve check pressure switch

• High gas fuel pressure shutdown switch

• Gas strainer

System requirements for the natural gas fuel are as follows:

• Requires a constant supply of gas at a maximum flow demand rate of 32.2 nm3/min (1200 sfm) at 1725-kPa-gauge (225 psig) minimum pressure. Gas fuel pressure is used to operate the fuel system pilot valve.

• The gas fuel should be free of sulfur, contaminants, entrained water, and liquid hydrocarbons

• Gas fuel must conform to Orion's Specification ES 9-98

VII. LUBE OIL SYSTEM

A complete lube oil system suitable for operation with lube oil conforming to Orion's Specification ES 9-224 is included. The lube oil system provides oil to the bearings in the Orion 5000 gas turbine engine, gear box and generator. Instrumentation, flow control and on frame piping are included.

Main Lube Oil Pump. An engine driven lube oil pump is provided with suction strainer.

Post Lube Backup Pump. A 1.5hp (1.1 kW) AC motor driven pump is provided to supply post operation lube oil flow in the event of power failure. Power is provided by a 24 VDC battery system through a VFD/ inverter.

Drain Line Sight Glasses. Sight glasses are provided on the drain lines from all gas turbine, generator and gearbox bearings. Note that some of the gas turbine bearings have a common drain line.

Lube Oil Tank. A 420-gallon operating capacity carbon steel lube oil tank is provided. The lube oil tank is integral with the package frame. Lube oil level indicator, fill connection with inlet strainer and drain connections are included.

Lube Oil Tank Heater. A thermostatically controlled 4.5 kW lube oil tank heater is provided. Electric power requirements are 460 V, 60 Hz, three phase.

Lube Oil Vent Separator. An off skid mechanical coalescer element is provided to remove oil vapor from the lube oil tank vent. Recovered oil drains back to the lube oil tank. Interconnect piping between the frame flanges and the vent separator is not included in Orion’s scope. The vent separator is nominally rated for less than 0.2 gallons/day (0.76 L/day) oil loss.

Lube Oil Cooler. An air/oil lube oil cooler is provided. The fan is driven by a 3.7 kW AC motor. The lube oil cooler is designed for off skid installation. Interconnect piping between the frame flanges and the lube oil cooler is included according to current design.

Lube Oil Type. Lube oil is not included. The lube oil supplied must be consistent with the requirements of Orion specification ES 9-224.

Lube Oil Filter. Single 5-micron oil filter units are provided with drain, fill and vent valves.

VIII. CONTROL SYSTEM

Orion Control System. The control system is provided and is a highly integrated programmable logic controller [PLC] based control system. The control system is installed on the package frame to minimize interconnect wiring.

The control system includes a microprocessor, remote communications modules, chassis based and flex input/output modules, line synchronization module, power supplies and a hardware backup shutdown system.

The control system provides for control of all phases of package operation to include start and shutdown sequencing, normal operation, and malfunction shutdown.

Vibration Monitoring. Vibration monitoring is provided to include three proximity probes, one per bearing, on the Orion 5000 engine. One accelerometer is provided with the gearbox. Two velocity transducers, one per bearing are provided with the generator. Preset warning indications and malfunction shutdown initiation are provided.

Temperature Monitoring. Temperature monitoring is provided to include the Orion 5000 engine thrust bearing, lube oil drains, lube oil header and the generator bearings and stator windings. Preset warning indications and malfunction shutdown initiation are provided. Ambient, lube oil tank and enclosure temperatures are also monitored.

Audible Alarm. An audible alarm horn is provided to sound whenever the unit has an alarm or shutdown condition. A horn silence push button is mounted on the face of the control panel.

Local Display. The control system is installed on the package frame in weatherproof enclosures. A digital control panel [DCP] with all of the necessary switches and indicators is provided. In addition to display of “first out” malfunctions, the DCP can display:

• System summary/normal running data

• System status

• Digital display of engine and generator parameters

• Alarms and Shutdowns

Engineering Units. Temperature data is displayed in of. Pressure data is displayed in pounds per square inch [psi].

Language. Package labels and screen displays are in English.

Supervisory Interface. An RS 232C/422-interface module is provided to give the user’s supervisory computer access to the Allen Bradley control system data. Limited control capability is provided to allow the supervisory computer to start and stop the unit, reset alarms, and raise/lower speed and load set points. The communications protocol is Allen Bradley’s DF1. The interface module may be located up to 10,000 feet (3,048 meters) from the turbine control system and located up to 50 feet (15 meters) from the supervisory computer for the RS 232C module or 4,000 feet (1,219 meters) for the RS 422 module. The modules are “table top” units and require 120 Vac, 50/60 Hz power.

IX. GENERATOR CONTROL AND MONITORING

Integrated monitoring and control of the generator is provided using a specially designed module in the PLC to receive input data from potential and current transformers. The system calculates real and reactive power, power factor and the variables required for synchronization.

Automatic Synchronizing. An automatic synchronizer is provided with the control system to automatically synchronize the unit to the bus through push-button control on the digital control panel [DCP] or by receipt of an appropriate remote signal. A synch check relay is provided as an additional permissive and for backup protection.

Motorized Voltage Adjust. Raise/lower voltage push button control is provided on the digital control panel to control a motorized potentiometer for voltage control. An additional raise/lower switch, supplied by others, may be used to control voltage from a remote location.

KW Controller. A kW import controller is provided to control the real load (kW) on the generator set while operating in parallel with a utility or other large source. The kW controller monitors the load imported from the utility source and adjusts the generator set fuel flow to maintain a pre-set level of imported power on the utility at all times. This control mode is for applications where it is desired to prevent any power from being exported to the utility. Protection against excessive kW load while in parallel with a large source is provided by the control system “T5" temperature limiter. The kilowatt load level select switch and adjustment is located on the digital control panel.

KVAR/Power Factor Controller. A kVAR/power factor controller is provided to maintain a constant reactive load (kVAR) output or constant power factor (pf) on the generator set while the unit is operating in parallel with a utility or other large source. The controller applies a signal directly to the voltage regulator adjust circuit to maintain a constant reactive load or power factor with changes in the infinite bus voltage level. The system incorporates a set point adjust rheostat to set the desired kVAR or pf, a selector switch to choose kVAR or pf control mode, and a switch to turn the controller on and off.

X. ADDITIONAL ANCILLARY EQUIPMENT

The following additional ancillary equipment is also provided for the turbine generating package:

1. Neutral Ground Resistor

2. Auxiliary Load Transformer (13.8 kV:480 V, 60 Hz). This transformer eliminates the requirement for an alternate 480VAC shore power supply.

3. Liquid Fuel Boost Pump (with dual fuel option)

XI. DRAWINGS

One set of standard drawings are provided with each ORION package.

XII. OPERATION AND MAINTENANCE MANUALS

One set of operation and maintenance manuals are provided with each package.

SECTION - 4

POWER CONTROL ROOM (PCR) BUILDING

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

The Power Control Room Building contains the following equipment:

• PCR HVAC system

• Generator Main Circuit Breaker

• Auxiliary Transformer Feeder Circuit Breaker

• Bus PTs, Feeder CTs, Metering CTs and PTs, and Protective Relay Module

• Lightning Arrestor and Surge Capacitor

• Motor Control Center (Serves Turbine Generator 480VAC Auxiliary Loads)

• 120VDC Turbine Generator Battery System with Charger

• Dedicated 120VDC Switchgear Battery System with Charger

• Start Motor Variable Frequency Drive (VFD)

• DC Backup Lube Oil Pump Contactor

• Interior Lighting

SECTION - 5

PERFORMANCE

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

Expected power output is 5,200 kW with a heat rate of 11,263 Btu/kW-hr at ISO conditions.

SECTION - 6

EMISSIONS

ORION 5000 - INDUSTRIAL POWER GENERATOR SET

NOx emissions for a gas only combustion system: 25 ppmv

NOx emissions for a dual fuel combustion system: Gas 42 ppmv

No. 2 Diesel 96 ppmv