Innovator PDF

Generator Set Manual
AEP Gas Power Systems Innovator Generator Set
(Picture from Corp. Comm.)
Manual
July 2001 The information in this publication is subject to change and product improvement. Copies of this and other publications can be obtained through the General Services Documentation Solutions department, a part of Office Services. Address comments to: Documentation Solutions P.O. Box 201 Tulsa, Oklahoma 74102-0201 (918) 599-2875 Copyright 2001 AEP Gas Power Systems LLC No claim to copyright is made for the material contained in Appendix B and C. AEP Gas Power Systems Innovator Generator Set Manual, version 0 No part of this publication may be reproduced in any form or by any means without written permission from AEP Gas Power Systems.
Contents
Product Overview ........................................................................................................................... 1 Overview..................................................................................................................................... 1 Innovator Diagram ...................................................................................................................... 3 Engine ......................................................................................................................................... 5 Gearbox....................................................................................................................................... 7 Generator..................................................................................................................................... 8 Control System............................................................................................................................ 9 Innovator Features and Spec Sheet ........................................................................................... 10 Installation..................................................................................................................................... 15 Overview................................................................................................................................... 15 Safety Considerations ............................................................................................................... 16 Site Preparation......................................................................................................................... 17 Receiving and Handling............................................................................................................ 18 Inspection.................................................................................................................................. 20 Pre-Installation Equipment ....................................................................................................... 21 Minimum Requirements ........................................................................................................... 22 Installation Detail...................................................................................................................... 27 Generator Storage and Preservation.......................................................................................... 30 Generator Storage and Preservation.......................................................................................... 30 Computer System...................................................................................................................... 31 Operation and Daily Maintenance ................................................................................................ 33 Overview................................................................................................................................... 33 Initial Start Check List .............................................................................................................. 35 Daily Running Check List ........................................................................................................ 38 Weekly Running Check List..................................................................................................... 41 30-Day Restart and Monthly Running Check List ................................................................... 42 How to Start Generator ............................................................................................................. 43 Post-Run Check (Shut Down)................................................................................................... 44 Emergency Shut Down ............................................................................................................. 45 Computer Operation.................................................................................................................. 46 Maintenance.................................................................................................................................. 49 Overview................................................................................................................................... 49 Oil System................................................................................................................................. 50 Fuel System............................................................................................................................... 57 Air System ................................................................................................................................ 59 Battery Maintenance ................................................................................................................. 60 Engine Compressor Section...................................................................................................... 63 Major Maintenance Schedule ................................................................................................... 64 Heavy Maintenance .................................................................................................................. 65 Maintenance Parts......................................................................................................................... 67 Recommended Parts List .......................................................................................................... 67 Troubleshooting ............................................................................................................................ 69 General Topics .......................................................................................................................... 69
AEP Gas Power Systems
Contents i
Appendix A................................................................................................................................... 75 Manufacturer Information List ................................................................................................. 75 Appendix B ................................................................................................................................... 77 Manufacturer Reference Manuals............................................................................................. 77 Appendix C ................................................................................................................................... 79 Material Safety Data Sheets...................................................................................................... 79 Appendix D................................................................................................................................... 81 Drawings ................................................................................................................................... 81
ii Contents
Preface
Notices
This manual outlines procedures for operating and maintaining the Innovator generator set using safe, effective methods. The procedures contain Notes, Cautions and Warnings, which should be followed, along with standard procedures to eliminate the possibility of personal injury or improper service, which could damage the unit. Although information in this manual is as complete as possible during the time of publication, the possibility exists that some information may not be current. AEP Gas Power Systems cannot assume the responsibility for any errors, changes or omissions that may occur in the compilation of this information.
Safety Precautions
WARNING The use of electric machinery can be hazardous. Installation, maintenance, and operation should be performed by qualified personnel; while adhering to all local, state and federal codes including, but not limited to, the National Electrical Code. For equipment covered in this manual, it is important to observe safety precautions to eliminate the possibility of personal injury and/or damage to the equipment. Among many considerations are the following: Avoid high temperature exhaust. Shutoff fuel/lockout before performing maintenance. Avoid rotating shafts and do not wear loose clothing in proximity of rotating machinery. Perform all maintenance in accordance with owners lockout/clearance procedures and safety policies. Wear hearing protection proximity of this equipment while in operation. See OSHA standard 1910.95 available at www.osha.gov. Do not install or operate unit near flammable liquid or materials storage and accumulations of trash or debris should be kept away from unit.
These instructions do not purport to cover all details for variations in equipment or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchasers purposes, the matter should be referred to American Electric Power Gas Power Systems, P.O. Box 1623, Columbus, Ohio 43216-1623
Preface iii
Product Overview
Overview
Introduction
The 1.2 MW Innovator generator set is based on well-known, time-proven components, together with a state-of-the-art operating system that operates in real time while providing true deterministic control. This continuous duty package is comprised of four main components Prime mover, Gear box, Standard generator, and A unique control system.
The Innovator 1200 is designed to run off gaseous fuel or liquid fuels. In this chapter, you will be able to identify and understand the components within the generator set.
Warranty Information
The warranty on the Innovator generator set is specified in sales contract. Tamper proof seals are provided on key engine components. Breaking or tampering with these seals voids the warranty. Warranty is also voided when use of non-recommended parts are installed for operation or maintenance. (See Recommended Parts List, page 67) Also, the warranty is voided when the use of non-recommended parts for operation or maintenance has taken place.
Continued on next page
Overview 1
Overview, Continued
In This Chapter
This chapter contains the following topics: Topic See Page 3 5 7 8 9 10
Innovator Diagram Engine Gearbox Generator Control System Innovator Features and Spec Sheet
2 Overview
Innovator Diagram
Part Identification
The photos below identify components from both long-side views of the Innovator. 3 2 1 4 5 6
16
Figure 1, Long-side Front
5 6 7
14
1 9
13
15 11 10
Figure 2, Long-side Back Continued on next page
12
Innovator Diagram 3
Innovator Diagram, Continued
Part Identification Legend
The legend for the Innovator line diagram is below. 1 Generator 2 Connection to switchgear/customer load 3 Relay Panel 4 Control Panel including Start, Stop and Emergency shut-off buttons 5 High-speed drive shaft within air intake scroll 6 Engine 7 Exhaust 8 Skid 9 Low-speed drive shaft with guard 10 Compressor dump system 11 Filler neck on engine oil tank 12 Engine and gearbox oil filters 13 Oil coolers 14 Air intake filter 15 Filler neck on gearbox oil tank 16 Pads
4 Innovator Diagram
Engine
About the Engine
The prime mover is a continuous duty, highly modified Avco Lycoming T53 Gas Turbine Engine. This aero-derivative engine has an impressive 40 million hour history of excellent performance and reliability. The engine has been modified to stringent AEP GPS specifications to accommodate multiple industrial applications requiring 1,400 +SHP at a variety of output shaft speeds up to 21,000 RPM. Its features are as follows: Split-shaft design with five-stage axial compressor One-stage centrifugal compressor Two-stage gas producer turbine Two-stage power turbine with onboard reduction gearing Output speed of 6,000 RPM Output up to 1,200 kW
Image
Below is a photograph of the engine.
Figure 3, Engine
Exhaust area will have high temperatures and airflow.
Engine 5
Engine, Continued
Sub-Systems
There are four sub-systems associated with the engine component of the generator set which are identified and described in the table below. Sub-System Lubrication System (engine only) Detail Requires 28 gallons of MIL-L-23699 Aeroshell 500 oil Oil pressure is set at 60-80 psi at 150F or 65C Pressure lube through a motor-driven gear pump with gravity return Closed-loop system Maximum engine inlet temperature of 200F or 93C 3 micron absolute spin-on oil filter Motor driven, temperature actuated, computer-controlled gearpump Cooling radiator with motor-driven forced air fan Customer supplied, 150 psi combustible gas Paper element, high-pressure gas filter Normally-closed emergency solenoid valve Computer-controlled fuel valve supplying four lines; two lines go to each of the two manifolds Each manifold contains 11 fuel distribution nozzles Computer-controlled capacitor discharge Four combustion chamber mounted spark igniters
Cooling System
Fuel (gas) System
Ignition System
6 Engine
Gearbox
About the Gearbox
Cotta Transmission Company developed the reduction gearbox. This gearbox was specifically designed and manufactured to produce either an 1,800 RPM or 1,500 RPM output to the generator. Its characteristics are identified below: Two gear pressure lube gravity return 3.32 to 1 reduction gearing assembly All main bearings have temperature sensors
Image
Below is a picture of the gearbox.
Figure 4, Gearbox
Sub-Systems
There are two sub-systems associated with the gearbox component of the generator set which are identified and described in the table below. Sub-System Lubrication System (gearbox only) Cooling System (same as engine cooling system) Detail Requires 14 gallons of MIL-L-23699 turbine oil Oil pressure is set at 20-25 psi at 100F or 38C Motor driven, positive displacement gear pump Maximum gearbox inlet temperature of 150F or 65C 3 micron absolute spin-on oil filter Motor driven, temperature actuated, computer-controlled gearpump Cooling radiator with motor-driven forced air fan Closed-loop system
Gearbox 7
Generator
About the Generator
The generator is built by Newage International Limited and is designed for easy installation, minimum operating vibration and rapid response to widely varying electrical loads. The generator consists of the following characteristics: 1,500 RPM (50Hz) or 1,800 RPM (60Hz) 4-pole generator On-board voltage control regulator On-board bearing temperature sensors and stator winding temperature sensors Two-bearing generator Synchronous generator Wye configuration 1500 MVA, 80% power factor
Image
Below is a picture of the generator.
Figure 5, Generator
Sub-Systems
There are two sub-systems associated with the generator component of the generator set which are identified and described in the table below. Sub-System Lubrication System Cooling System Detail Sealed bearings or grease fitting bearings, depending on unit provided On-board generator driven suction fan
8 Generator
Control System
About the Control System
The Innovator Control System is an advanced and highly reliable feature. The Innovator control was developed by AEP GPS engineers in cooperation with OMNX Direct Control, a division of Olin Corporation. It offers a direct connection between the I/O and processor eliminating relays, timers and PLCs. The signals are processed at speeds up to 1ms update rate providing speed and stability surpassing traditional control systems. The Control System has a Man Machine Interface (MMI) with graphics help and information. The input/output interface is a Computer Machine Interface (CMI). The Control System features are described below. PC-based, multi Input/Output, multi-function real-time direct control system 2 analog outputs control fuel valves and linear actuators 30 analog inputs control pressure speed and temperature 14 digital outputs control various relay functions 4 digital inputs sense activation of remote relays PC included on generator unit Outputs available for monitor, keyboard and mouse Remote monitoring capabilities using networking or telecommunications
Image
Below is a picture of one screen of the control system.
Figure 6, Screen of Control System
Control System 9
Innovator Features and Spec Sheet
Innovator
Below is a picture of the Innovator generator set.
Figure 7, Innovator Generator Set
Features
Features of the Innovator generator set are listed below. Industrial gas turbine package Compact, integrated package providing ease of installation Factory tested Liquid or gaseous fuel capability On-skid PC-based control system
Spec Sheet
Package Arrangement information is contained in the table below. Part Gas Turbine Main Reduction Gear Drive Description Innovator industrial twin shaft 5-stage centrifugal compressor section Annular combustion chamber - 22 fuel injectors Oil temperature and pressure, exhaust gas temperature monitoring Independent lube oil circulation and cooling system Single reduction 1,800 or 1,500 RPM output speed Oil temperature and pressure, bearing temperature monitoring Independent lube oil circulation and cooling system
10 Innovator Features and Spec Sheet
Innovator Features and Spec Sheet, Continued

Spec Sheet (continued) Part Generator Description 1500 MVA, 80% power factor Salient pole, 3-phase, 6-wire, wye connected, synchronous with brushless exciter Open drip-proof construction Ball bearings Solid state voltage regulation with permanent magnet generator NEMA Class H insulation with H Rise Continuous duty rating Phase winding temperature and bearing temperature monitoring Steel base with drip pans Direct drive DC starter Natural gas fuel system PC based Generator control Pressure and temperature monitoring DC electric drive lube oil pumps DC electric drive post lube oil pumps Individual engine and gearbox air/oil coolers Individual engine and gearbox air/oil tanks Spin-on lube oil filters Mechanical demister placed on the engine oil tank vent Operation and maintenance manuals Drawings Maintenance schedule Operational check sheets Test reports Approximately 374 mscf per day of natural gas at full load
Package
Control System
Gas Turbine Engine and Gearbox Lube Oil Systems Lube Oil Demisting System Documentation
Fuel Consumption
Innovator Features and Spec Sheet 11

Spec Sheet (continued) Part Full Load Factory Testing of Gas Turbine and Package Auxiliary Power Description Each unit will be tested prior to shipment Reports will be included with unit
The skids auxiliary components (oil, pumps, cooling fans, controls, starters, etc.) are powered by a 24-volt DC power system. On-board batteries supply the power for starting and operating the generator set, but by themselves cannot sustain operation of the generator set. Power to maintain the batterys charge and sustain the operation of the generator set can be provided by the following: A 24-volt DC engine powered auxiliary power unit An AC house powered rectified 24-volt DC battery maintaining/charging system An on-board optional belt driven alternator providing black start (see below) capability. The skid is provided with 24-volt DC motors on oil pumps, fans and starters. As an option, AC motors can be supplied if AC power is available from an external source. Black start is defined as having the optional installed components that allow the generator set to start and operate with no external power available. The black start components consist of a skid mounted, belt driven 375 amps 28.8-volt DC alternator. This alternator is capable of providing power to operate the generator sets 24volt DC auxiliary components and controls, as well as recharge the starting batteries. For black start capability, a 150 psi high pressure gas source is required.
Black Start
Nominal Performance Ratings
The Nominal Performance Ratings are listed in the table below. No inlet or exhaust loss; ISO conditions, pipeline natural gas fuel with LHV+31.5 to 43.3 MJ/nm3 (800-1100 BTU/scf) Category Output Power kWe ISO: 15 degrees C (59F), sea level Heat Rate, kJ/kWe-hr (BTU/kWe-hr) Exhaust Flow kg/hr (lb/hr) Exhaust Temperature, C (F) Fuel Consumption (mscf) Nominal Performance Rating 1,200 14227 (13,485) 18,897 (41,700) 578 (1,072) 374
Optional Equipment and Services
The Optional Equipment and Services available are in the table below.
Part Generator Options
Fuel Systems
Lube Oil System
Control System
Accessory Equipment Enclosure
Description Standard duty rating Standard voltages: 330, 3,300 at 50 Hz; 480, 4,160 at 60 Hz Liquid (such as diesel and #2 fuel oil) Alternate fuels (such as naptha, propane, and low BTU methane) Water/oil lube oil cooler Electrostatic demister Lube oil tank heater Remote display/control terminal Heat recovery application interface Remote supervisory interface kW control KVAR/power factor control Vibration monitoring Turbine cleaning system: on-crank and on-line Package lifting kit Optional weatherproof /acoustic enclosure
Innovator Features and Spec Sheet 13

Optional Equipment and Services (continued) Part Ancillary Equipment: Various Air Inlet and Exhaust Systems Switchgear Description Inlet and exhaust silencers Self-cleaning or prefilter/barrier inlet filter Inlet evaporative cooler Exhaust gas SCR clean-up system Independent operation Parallel operation All switchgear must meet the appropriate federal, state and local requirements; for example, the National Electric Code (United States).
Installation
Overview
Introduction
Install the generator in accordance with the National Electrical Code and consistent with sound practices and all legal codes. Installation requirements for the Innovator generator set are site specific. For example, the installation may be permanent, temporary, emergency or portable. After reading this chapter, you will understand several safety concerns, site preparation, receiving and handling, and all customer pre-installation and AEP GPS pre-installation requirements. The customer is responsible for adhering to all federal, state and local codes.
In This Chapter
This chapter contains the following topics: Topic Safety Considerations Site Preparation Receiving and Handling Inspection Pre-Installation Equipment Minimum Requirements Installation Detail Generator Storage and Preservation Computer System See Page 16 17 18 20 21 22 27 30 31
Overview 15
Safety Considerations
Overview
The following are safety items to consider when installing and operating the generator set. This information is not intended to be a complete list of all safety items to consider. Please consult your plant safety manual, federal, state and local codes for more complete information.
Cautions
Exercise caution and take necessary precautions in the following areas: Category Decibel Level Weight Level Caution The decibel level of the Innovator generator set is 113 db at 3 feet from the inlet. The weight of the generator set is approximately 20,000 pounds. Exercise caution during installation and in the decision-making process for the designated installation location. Gaseous fuel is flammable. Exhaust area will have high temperatures and airflow.
Fuel Exhaust
MSDS See Appendix C, page 79 for MSDS on oil, batteries, gas and (Material safety diesel fuel. data sheets)
16 Safety Considerations
Site Preparation
Requirements
Meet the following requirements before installing the generator set. Prepare a clear, level area Position unit so prevailing winds are on long side of unit container, not at either end of unit Place generator set unit in proximity to grid power connections (if applicable) Clear exhaust area Cover ground with gravel and seal for dust control Set unit on level piers, foundation or a pad capable of withstanding 14,620 pounds for bare skid or 20,000 pounds for enclosed unit Install security fence surrounding unit within local, state and federal codes Maintain the appropriate distance surrounding the unit for noise abatement within local, state and federal codes Install in a location that can be kept clean and free of blowing dust, dirt and trash Keep location isolated from vibration sources especially near 1,800 RPM
Floor Loading
The area that the skid is place upon shall be capable of supporting 200 lb/in2.
Support Points
The skid is designed to rest on four load pads to properly support the unit and provide correct alignment of the equipment on the skid. There shall be no support rather than that of the pads.
Weights
The overall dimension of the generator set is 17 feet by 6 feet. The following table identifies the weight of the unit and components. Part Gearbox Generator Skid and Engine Ring Engine Oil and Oil System Misc. Electric and Mechanical Auxiliary Components Total Weight Weight 1,000 lb 6,060 lb 3,500 lb 650 lb 500 lb 2,910 lb 14, 620 lb
Site Preparation 17
Receiving and Handling
Receiving the Generator Set
Immediately upon receipt, carefully unpack and examine unit for any damage sustained in transit. If damage is observed, try to establish responsibility for the damage and report the damage to the carrier and American Electric Power Gas Power Systems immediately. Unless specifically called for on the requisitions, the equipment is not suitably packed for long-term outside storage.
Handling the Generator Set
Review the following guidelines before handling the generator set. Safe practices and careful handling are important to avoid injury to personnel and damage to equipment. The equipment is provided with lifting lugs to which cables or chain hooks may be attached for lifting units. Do not lift the complete generator set by using the lifting lugs of individual components. Use slings or chokers with the appropriate lifting capacity for lifting the entire generator skid. Attach slings through lifting lugs along the skid beam and to lifting point on generator end. It is recommended that a spreader bar be used in conjunction with lug attachment points and lifting points. Take extreme care to prevent a lifting chain from bearing against the engine, gearbox, generator, junction boxes, and radiators. Lift the generator set without twisting or bending of the base to avoid causing misalignment or distortion of the base and subsequent component misalignment.
Failure to follow this procedure can result in base distortion, coupling misalignment, and the corresponding vibration and damage to bearings and couplings.
18 Receiving and Handling
Receiving and Handling, Continued
Storage
The generator set often arrives at the installation site before it can be permanently located on the foundation. Care must be taken to protect the generator whether it is stored in a building or outdoors. In either case, the installer must take the special precautions described below. Location Outdoor Precautions Inspect equipment for damage during shipment. Prepare the installation site with adequate drainage. A crushed rock surface is suggested. Store the generator set off the ground on blocks such as railroad ties. This will minimize moisture pick-up from the ground and make inspections easier to accomplish. Do not enclose the machines in polyethylene so that air cannot circulate. A small amount of circulating air is necessary to prevent humidity reaching the level at which sweating occurs. Moisture can cause electrical failure of insulated winding and/or the mechanical failure of highly stressed armature glass banding. Keep the machines slightly warmer than the room air by safe, reliable heaters. Electric heaters are suitable for this purpose. Store the generator set in a clean, dry room, which is not subject to sudden changes in temperature. Varying temperatures may cause the machines to sweat and result in corrosion of a part or even damage from freezing. Store the generator set off the ground on blocks such as railroad ties. This will minimize moisture pick-up from the ground and make inspections easier to accomplish. Do not enclose the machines in polyethylene so that air cannot circulate. A small amount of circulating air is necessary to prevent humidity reaching the level at which sweating occurs. Moisture can cause electrical failure of insulated winding and/or the mechanical failure of highly stressed armature glass banding. Keep the machines slightly warmer than the room air by safe, reliable heaters. Electric heaters are suitable for this purpose.
Indoor
Receiving and Handling 19
Inspection
Prior to Installation
Carefully inspect the generator before installing generator set. Remove items listed below before installation: Any temporary protective coatings Any shipping covers and braces
During Installation
Carefully protect items listed below during installation to avoid damage from paint spray, weld splatter, welding rod butts, or metal chips from files and grinders, which could fall onto the generator. Bearings Terminal Box Windings
General Inspection
Follow inspection procedures before starting the machine for the first time, after an extended shut down, or after extensive maintenance or repair. Be sure to check the following items: Check air passages to make sure they are free from all foreign objects, such as dirt, lint, old rags, wood chips, metal particles, or rodent nests If necessary, blow out the windings with clean dry air Inspect couplings for damage prior to operation and check all fasteners for tightness
20 Inspection
Pre-Installation Equipment
Customer Supplied
The customer needs to meet the following requirements prior to installation of the generator set. Equipment Fuel Supply Gas System Interconnect Equipment Detail Approved combustible gaseous system 150 psi at 16 million BTUs per hour at maximum performance All piping/plumbing required as per local, state and federal codes All connection cables, switchgear and interconnect equipment as per local, state and federal codes The interconnection of the Control System to the switchgear must be tailored to the customers specific equipment When connecting the unit, carefully follow the instructions in the switchgear, paralleling unit if applicable, and this manual CFM based on site specifications Appropriate forklift or crane Appropriate fire suppression equipment is required when customer supplies unit container
Air Filtration
Installation Equipment Fire Suppression
AEP GPS Supplied
AEP Gas Power System will meet the following pre-installation requirements. Equipment Gas Filter Detail Supplied based on site specifications Customer (or customers contractor) must install gas filter based on manufacturer recommendations (See How to Change High Pressure Gas Filter, page 57) Customer (or customers contractor) must install emergency shut-off in accordance with fuel source and Innovator generator set control valve within approved procedures An AEP GPS Field Technician can be made available to assist in a supervisory capacity during the initial start-up procedure Appropriate fire suppression equipment will be provided when AEP GPS supplies the generator set in an enclosure
Emergency Shut-Off Initial Start-Up
Fire Suppression
Pre-Installation Equipment 21
Minimum Requirements
Air Filtration
The following are the minimum airflow/ventilation requirements at the air inlet. Air Volume Filter Minimum Requirements 14.2 lb/second (85 scfm) at inlet at iso-conditions Must support the air volume amount of airflow under worstcase conditions
Personnel Training Requirements
Operator and maintenance personnel must be qualified, properly trained and familiar with manual to avoid injuries and accidents. AEP GPS can provide a training course for operators.
Switchgear Interface Requirements
Grid independent operators must follow NEC or other local authorities requirements for disconnection devices and protection schemes. For grid parallel operation, equipment must meet the requirements of the NEC or other appropriate local codes. Interface with the utility must also meet the requirements of the local utility.
Electrical Installation Requirements
On-site electrical interconnection requirements vary widely. Adhere to your plant safety manual, federal, state and local codes.
22 Minimum Requirements
Minimum Requirements, Continued
Natural Gas Supply Piping Requirements
See figure and requirements below for Natural Gas Supply Piping.
Generator
Gear Box
Engine
Fuel Control Valve
4 Flex hoses connected to fuel manifold
Flange 3" pipe
Emergency Shut Off
Owner Supplied Hand Shut Off Valve Gas Filter Gas Source
Figure 8, Natural Gas Supply Piping
Label Field Run Source Piping Flanges External Hand Shut Off
Requirements According to location Either from high-pressure gas main with metering and regulators to approximately 150 psig or from off-skid gas compressor with approximately 150 psig output pressure To be 3 Schedule 80 seamless ASME SA106 Grade B carbon steel with welded fittings installed by certified welders and in accordance with NFPA 37 (owner supplied) To be 3 150 lb class ASME SA105 carbon steel with gaskets (owner supplied) Shall be 150 lb class, carbon steel body (ASME SA105) gate, globe, or ball valve (owner supplied)
Minimum Requirements 23
Grid Interface
The Innovator is designed with the ability to interface with the electric grid. Several pieces of equipment must be installed to facilitate grid paralleling. They are listed here: Generator On board generator operating system Electrical circuit breaker Metering instruments Synchronizing control Generator controller Protective relays
Operation & Connectors
In the grid parallel operation setup, the generator on board operating system controls the start up of the generator. When the unit is up to temperature and operating at idle, the control is shared with the synchronizing control. That control compares the power wave form of the utility system with that of the isolated generator and provides a signal to the generator control to speed up the generator or slow it down to pull the two signals into synchronization. In grid parallel operation, a power factor controller must be installed so that power factor can be controlled instead of voltage. If voltage is controlled, the unit will try to support low voltage on the grid and overload the generator. When the waveforms of the utility and the generator match, the circuit breaker is closed to electrically attach the generator to the grid. The generator is then loaded to the set point by a signal from the generator controller. The generator controller continues to issue signals to the generator operating system calling for changes or corrections in the load level. Unit comes equipped with a power factor control card for voltage control. In this situation, the AVR control is not connected. To control the voltage from the voltage sensor in the switchgear, the AVR control signal can be applied. Review instruction in the Stamford Newage generator manual see Appendix B, page 77. The innovator control system must have signals from the synchronizing control. The signals are:

Operation & Connectors (continued) Component Speed/load control Signal 4-20 ma Direction From switchgear to on board operating system generator control From switchgear to on board operating system generator control From switchgear to on board operating system generator control On board operating system generator control to switchgear On board operating system generator control to switchgear From switchgear to on board operating system generator control From switchgear to on board operating system generator control From switchgear to on board operating system generator control From switchgear to on board operating system generator control (PFC-3) Connector CP4A-1 + CP4A-7 CP4C-6 CP4C-12 CP4C 4 CP4C 10 CP4A-3 CP4A-9 CP4C-3 CP4C-9 CP4C-5 + CP4C-11 CP4A-2 CP4A-8 CP4A-6 CP4A-12 To be assigned
AVR control (see caution above) Main breaker status
+- 3 volts
Contact closure
Turbine ready signal Turbine failure signal Generator kW
Contact closure Contact closure 4-20 ma
Emergency valve shut down Electrical Trip
Contact closure
Contact closure
Switchgear breaker closed
Contact closure
Minimum Requirements 25
Diagram
The diagram below identifies the pin connector arrangement (Phoenix Connector).
Figure 9, CPA Cannon Plug #4
Installation Detail
Innovator Connections Long-side Front
The following table and diagram identify connection locations and requirements on the Innovator long-side front.
1 - Electric Connection (out)
2 - Oil coolers
3 - Phoenix Connector(s)
Figure 10, Innovator Lon-side Front
Item 1 2 3
Part Electric Connection (out) Oil Coolers Phoenix Connector(s)
Requirement Connect power cables from this location to protection breaker Utilize proper air flow, see Air Filtration, page 22 Insure proper installation, see Operation & Connectors, page 24
Installation Detail 27
Installation Detail, Continued
Innovator Connections Long-side Back

1 - Exhaust
The following table and diagram identify connection locations and requirements on the Innovator long-side back.
3 Engine Manifold
2 Fuel Valve & Emergency Shut-off
Figure 11, Innovator Long-side Back
Item 1 2 Exhaust
Part Fuel Valve and Emergency Shut-off Engine Manifold
Requirement Install exhaust stack Install fuel valve and emergency shutoff; fuel valve manifold connects to engine manifold; see Fuel Valve, page 29 Connects to fuel valve manifold
28 Installation Detail
Installation Detail, Continued
Fuel Valve
Below is a close-up view of the fuel valve components. Fuel Valve Hose connections
Emergency Shut-off
Figure 12, Fuel Valve
Phoenix Connector
Several Phoenix Connectors require installation on the Innovator. Below is a closeup view of one.
Figure 13, Phoenix Connector
Generator Storage and Preservation 29
Generator Storage and Preservation
Overview
If the generator is inactive or disconnected for a month or longer, the machine needs to be inspected. Take the following steps to maintain the equipments condition. Scenario Disconnected and Stored Actions Rotate the turbine shaft at least monthly to reduce bearing wear. Do not store the machine where there is a high degree of vibration that will wear the bearings at rest. Observe finished surfaces of the machine. If corrosion is forming, remove rust and coat with a rust preventative such as a light oil or silicone-based product such as WD40. Check oil tanks for water condensation and drain if water is found. Keep under cover to minimize damage from weather conditions. Rotate the turbine shaft. Check oil tanks for water condensation and drain if water is found. Inspect piping for damage that may result in leaks and repair if found. Inspect for unsafe conditions.
Unit is Connected but Inactive
30 Generator Storage and Preservation
Computer System
Operation
The following table identifies the sequence of events of the generator set computer during commissioning or installation. The AC power must be connected to the receptacle at the relay box. The computer power switch at top of computer should be in the on position. It is recommended that the generator set computer stay on from installation/commissioning forward, unless software changes are required.
Stage 1
Description Two power light will illuminate on the upper and lower back boards If lights do not come on, see Troubleshooting section, page 69.
2 3 4 5
QNX command prompt appears; #/> Login takes place Directory is changed to /process/unit1a;loadbank Connects to overview gas gen
Photograph
Below is the interior of the control box.
Main Computer
Figure 14, Innovator Generator Set Computer
Computer System 31
Operation and Daily Maintenance

Overview
Introduction
This chapter provides instruction on generator set operation, daily maintenance and emergency shutdown features. Follow all safety requirements provided by plant safety manual and local, state and federal codes.
In This Chapter
This chapter contains the following topics: Topic See Page 35 38 41 42 43 44 45 46

Initial Start Check List Daily Running Check List Weekly Running Check List 30-Day Restart and Monthly Running Check List How to Start Generator
Post-Run Check (Shut Down)
Emergency Shut Down Computer Operation
Overview 33
Overview, Continued
Utility Interconnection Mode
Below is a flowchart of the operation of the generator set with a transfer switch between customer load and utility interconnection. The transformer may also be located between transfer switch and utility rather than protection breaker and transfer switch shown here.
Load
Innovator generator set
Protection Breaker
Transformer (See note above)
Transfer Switch
Synchronizing Switchgear Utility
Figure 15, Flowchart of Operation of Generator Set with Utility
Island Mode
Below is a flowchart of the operation of the generator set with customer load.
Innovator Generator set
Protection Breaker
Transformer
Load
Figure 16, Flowchart of Operation of Generator Set with Customer Load
34 Overview
Initial Start Check List
About This Check List Check List
This initial start check list investigates primary areas prior to generator set start-up.
Follow each step in the checklist provided and document current condition or level. If any step does not pass the investigation, proceed to maintenance or troubleshooting areas to rectify problem prior to start-up. High temperature and airflow will exist at exhaust. Component Engine Step 1 Action Check and record engine oil level within limit levels See Maintenance section, page 49, for instructions and diagrams Check for visible leakage on plumbing and hose connections Check exhaust pipe for clearance (no obstructions) Check intake filters and area for clearance (no obstructions) Check fuel inlet valve and manifold lines for cracks, deformities, loose fittings or other damage Check security of engine mounting hardware, support ring mounting hardware, and wiring harness uniformity (no frayed wires, etc.)
Log
2 3 4 5 6
Initial Start Check List 35
Initial Start Check List, Continued

Check List (continued) Component Engine (continued) Step 7 Action Check battery condition, water levels, connection tightness and corrosion See Maintenance section, page 49, for instructions and diagrams Check for clamp tightness, safety, deformity of shaft and any foreign debris Check mounting security Check wiring harnesses for uniformity Check flanges, pipes and hose for leaks Check and record oil level within limit levels See Maintenance section, page 49, for instructions and diagrams Check security of low-speed drive shaft, coupling spacers and shim packs Check 24-volt alternator drive belt and pulleys for wear, deformity, cracks or missing cogs (if applicable)
Log
High Speed Drive Shaft Gearbox
1 1 2 3 4
5 6
36 Initial Start Check List
Initial Start Check List, Continued

Check List (continued) Component Low-Speed Drive Shaft Step 1 2 3 Generator 1 2 3 4 5 Oil Cooling System 1 2 Action Check to insure the guard is installed and secure Check security of coupling spacers and shim packs on both ends Check for applicable warning signs of shim pack breaking; rust streaks for example Check mounting hardware to insure tightness Check for visible grease leakage from bearings Check security of high-voltage connections Check grounding grid connection Check to be sure inlet and exhaust air passages are clear Check plumbing hoses and flanges for leakage Check oil filters to insure tight fit, no damage or leakage (engine and gearbox) See Maintenance section, page 50, for instructions and diagrams Check oil cooling fans for obstructions Check oil cooler exit for obstructions Check relay box and control box for mounting security; check for foreign objects and to be sure inlet and exhaust air passages are clear Check security of Phoenix connectors to insure no damage, still in sockets and locks down Check for standing alarms Check skid isolation-vibration pads for condition (cracks, bends) Check skid general condition (welds, level) Log
3 Control System 4 1
2 3 1 2
Skid
Initial Start Check List 37
Daily Running Check List
About Daily Running Check List
The items on this check list can be performed from the computer screen. If checked items are out of limits, visually inspect to determine if maintenance is required. Maintain a log of temperatures and pressures to enhance maintenance forecasting.
Check List
Check that the following parameters are within set ranges: Component Bearing Temperature Step 1 2 If Then Within Log acceptable limits Outside of See Troubleshooting, High acceptable bearing temperature, page limits 69 Observe exhaust gas temperature Action Observe bearing temperature Log
Exhaust Gas Temperature
1 2
Fuel Pressure
1 2
If Then Within Log acceptable limits Outside of See Troubleshooting, High acceptable exhaust gas temperature, limits page 69 Observe fuel pressure If Within acceptable limits Outside of acceptable limits Then Log See Troubleshooting, Low fuel pressure, page 69
38 Daily Running Check List
Daily Running Check List, Continued

Check List (continued) Component Step Action Generator Winding 1 Observe winding temperatures Temperatures 2 If Then Within Log acceptable limits Outside of See Troubleshooting, acceptable High generator winding limits temperature, page 69 Oil Level 1 Observe oil level 2 If Then Within Log acceptable limits Outside of See Troubleshooting, acceptable Engine oil below limits recommended level, page 69 Oil Pressure 1 Observer oil pressure 2 If Then Within Log acceptable limits Outside of See Troubleshooting, acceptable High/low lube oil limits pressure, page 69 Oil Temperature 1 Observe oil temperature 2 If Then Within Log acceptable limits Outside of See Troubleshooting, acceptable High/low lube oil limits temperature, page 69 Log
Daily Running Check List 39
Daily Running Check List, Continued

Check List (continued) Component Output Voltage Step Action 1 Observe output voltage 2 If Then Within Log acceptable limits Outside of See Troubleshooting, acceptable High/low output voltage limits page 69 1 Observe output kW 2 If Then Within Log acceptable limits Outside of See Troubleshooting, Low acceptable Output kW, page 69 limits Log
Output kW
Photograph
Below is a portion of the range screen of the computer system.
Figure 17 , Range Screen
40 Daily Running Check List
Weekly Running Check List
About This Check List
This Weekly Running Check List investigates primary areas while generator is in operation. If conditions warrant, the generator set may need to be shut down to make proper and safe repairs. Follow the same procedures as outlined in Initial Start Check List on page 35, and add the following steps to the appropriate component. Component Engine Gearbox Generator Step Action 7 Check for unusual noises or vibration 7 Check for unusual noises or vibration 6 Check for unusual noises or vibration Log
Weekly Running Check List 41
30-Day Restart and Monthly Running Check List
About This Check List
The 30-Day Restart and Monthly Running check list investigates primary areas prior to generator set restart and monthly running check. AEP Gas Power Systems recommends shutting down the generator set monthly and performing these checks if it is in continuous operation. Follow the same procedures as outlined in Initial Start Check List on page 35, and add step 4 below to the Control System section. Component Control System Step 4 Action During monthly shutdown operate emergency trip to insure emergency gas shutoff valve operates properly Log
42 30-Day Restart and Monthly Running Check List
How to Start Generator
Start Sequence
Follow the steps below to start the generator set.
Step 1 2 3
Action Complete pre-start check form, page 35 Push Start button (green) Listen for pumps
Result Generator set ready for start-up Engine and gearbox pumps begin running Once pressure and flow are established: Starter engages Ignition comes on Fuel flow initiates Exhaust gas temperature rises Starter disengages Engine stabilizes at idle speed
Image
Below is a picture of the Start button.
Start Button
Figure 18, Start Button
How to Start Generator 43
Post-Run Check (Shut Down)
Shut-Down Sequence
Follow the steps below to shut down the generator set.
Step 1
Action Push Normal Stop button
Result The engine reduces to idle: Customer load disconnects Engine stabilizes for 1 to 2 minutes Fuel flow shuts off Engine coasts down to minimal rotation speeds Engine and gearbox pumps shut off Generator set is ready for pre-start sequence
Listen for pumps
Image
Below is a picture of the Normal Stop button.
Normal Stop Button
Figure 19, Normal Stop Button
44 Post-Run Check (Shut Down)
Emergency Shut Down
Emergency Shut-Down Sequence
Follow the steps below to shut down the generator set in an emergency situation.
Step 1
Action Push Emergency Shut-Down button (red)
Result Emergency fuel valve closes Fuel control closes Engine goes to immediate shut down Coast-down time is 3 to 5 minutes
Wait for generator set to shut down
Image
Below is a picture of the Emergency Stop button.
Emergency Stop Button
Figure 20, Emergency Stop Button
Emergency Shut Down 45
Computer Operation
How to View Operation
Follow the procedures outlined below to view generator operation from remote network computer. The generator unit computer must be running, see Computer System, page 31.
Step 1
Action Start remote computer then login with assigned name and password. Login name and password are customer specific.
Prompt #/> will appear. Enter command as follows: cd //node#/process/unit1a There is a space between d and / The node # will be assigned, for example cd //4/process/unit1a
Enter the following commands based on your view preference: Custom options are available for customer specific requirements Graphic screen data requires mouse operation to view data See Control System, page 9 for graphic screen photograph See Photograph, page 47, for text screen image If Text based information Graphic based information Then Type overview gas gen Then you may page through data to view data of your choice. Type windows Right click, select programs Left click on programs, select turbine start
46 Computer Operation
Computer Operation, Continued
Shutdown
Follow the instructions below to shut down viewing capability. If Text based information Graphics based information Then Type vx Close window as normal by clicking on x in upper right corner Prompt #/> will appear, type cd / then hit enter Shut down remote computer by power in off position There is a space between d and /
Photograph
See image below for text based information screen.
Figure 21, Text information screen
Computer Operation 47
Maintenance
Overview
Introduction
This chapter leads you step-by-step through the general maintenance of the generator set including the oil, fuel, air, and battery systems.
Daily Maintenance Reminder
Periodically look for peeling paint, cracked hoses, corrosion, etc. This should be an ongoing daily practice. If you encounter any of these, refer to the Troubleshooting section, page 69, for guidance.
In This Chapter
This chapter contains the following topics: Topic Oil System Fuel System Air System Battery Maintenance Engine Compressor Section Major Maintenance Schedule Heavy Maintenance See Page 50 57 59 60 63 64 65
Overview 49
Oil System
About Oil System
Recommended oil changes are every 2,500 operating hours for the gear box oil system or as needed based on operating conditions and 10,000 operating hours for the engine oil system or every 18 months which ever comes first. Oil filter changes are recommended every 1000 hours or as needed based on operating conditions. More frequent changes may be required in severe operating conditions. Dispose of oil using current approved local, state and federal procedures. Following the initial 350 operating hours, change the gearbox oil as part of the initial break-in.
Material List (Customer Supplied Parts)
Keep the following items on hand when conducting maintenance on the oil system: Oil filter Approved oil, (MIL-L-23699 Aeroshell 500 Turbine Oil) 42 gallons total (28 gallons for engine, 14 gallons for gearbox) Approved 30-gallon container (engine) or 15-gallon container (gearbox) Type-compatible suction pump (Suction method only)
Predictive Maintenance
The following predictive maintenance is recommended. They may give indications of the overall condition of the lubricated components and be indicative of any future maintenance needs. Take oil samples every 6 months and send for laboratory analysis to check for oil condition, contaminants, or foreign materials Cut used oil filters open and visually inspect for metal filings or other foreign materials. Flakes of metal appearing in the filter, is a sign to perform maintenance. Determine source of metal.
50 Oil System
Oil System, Continued
Methods to Change Oil
There are two methods that can be used to change the oil. Suction method Drain plug method Use suction method of oil changing if the drain plug is not accessible on the bottom of oil tank.
Images
Below is a picture of one view of the oil filters.
Oil Filters
Figure 22, Oil Filters Continued on next page
Oil System 51
Images (continued)
Below are pictures illustrating how to change the oil.

Engine Oil Tank Oil Filler Neck
Figure 23, Engine
Oil Dipstick Holder
Gearbox Oil Tank
Put oil dipstick in oil filler neck until it reaches bottom of tank to check oil level
Oil Dipstick Holder
Figure 24, Gearbox Continued on next page
52 Oil System
How to Check the Oil
Checking the oil is the same for both the engine and gearbox. Follow the procedure below to check oil levels. Step 1 2 Action Open filler neck Insert dipstick in filler neck until it reaches the bottom of the oil tank Read indicated level If Then Within acceptable limits Close filler neck Less than acceptable limits Add oil (if necessary, see How to Change Oil, page 53)
How to Change the Oil - Suction Method
Changing the oil is the same for the engine and gearbox. Follow the step-by-step instructions for the suction method.
Step 1 2 3 4 5
Action Gather necessary materials (see Material List, page 60) Shut down the Innovator generator set by following Post-Run Check (Shut Down) procedure, page 44 Install safety locks so that the Innovator generator unit cannot be restarted; follow plant-approved safety procedures Install suction lines in oil filler neck and place oil container (30-gallon for engine or 15-gallon for gearbox) in appropriate position to receive oil Activate oil suction pump to remove oil 30-gallon container required for engine oil and 15-gallon approved container for gearbox oil Activate cooling pumps momentarily (5 to 10 seconds), after draining oil, to purge cooling system to remove any remaining oil in pumps. Remove top of stainless steel tank and clean using plant-approved safety procedures, if additional cleaning is needed Remove suction pump Add 28 gallons of approved oil for engine oil reservoir and 14 gallons for gearbox reservoir. Replace oil filter (see How to Change the Oil Filter, page 56) Activate cooling pumps and insure oil flow (by listening for inrush of oil in top of tank). See Troubleshooting section, page 69, if oil is not flowing.
6 7 8 9 10 11
Oil System 53
Images
Below are pictures illustrating oil change by suction method.

Suction Line in Oil Filler Neck Suction Pump and Container Add Approved Oil
Figure 25, Changing Oil by Suction Method Oil Filler Neck Continued on next page
54 Oil System
How to Change the Oil DrainPlug Method
Changing the oil is the same for the engine and gearbox. Follow the procedures below if the drain-plug method is utilized.
Step 1 2 3 4 5 6 7 8 9 10 11
Action Gather necessary materials (see Material List, page 60) Shut down the Innovator generator unit by following Normal shut-off procedure, page 44 Install safety locks so that the Innovator generator unit cannot be restarted. Follow plant-approved safety procedures. Put 30-gallon (engine) or 15-gallon (gearbox) minimum container under drain plug located at bottom of stainless steel tank Remove drain plug Activate cooling pumps momentarily (5 to 10 seconds), after draining oil, to purge cooling system to remove any remaining oil in pumps Remove top of stainless steel tank and clean using plant approved safety procedures, if additional cleaning is needed Replace plug on bottom of tank Add 28 gallons of approved oil for engine oil reservoir and 14 gallons for gear box reservoir Replace oil filter (see How to Change the Oil Filter, page 56) Activate cooling pumps and insure oil flow (by listening for inrush of oil in top of tank). See Troubleshooting section, page 69, if oil is not flowing.
Oil System 55
How to Change the Oil Filter
Follow the steps below to change the oil filter.
Step 1 2 3 4 5 6 7
Action Gather necessary materials (see Material List, page 60) Shut cooling pumps down (engine and transmission) Remove filter by spinning off (use appropriate tools) Fill new filter with two quarts of approved oil Install new filter by spinning on, as stated by manufacturer recommendations Reenergize cooling pumps Check for leaks
Image
Below is a picture illustrating how to change the filter.
Remove Filter by Spinning Off
Figure 26, How to Change the Filter
56 Oil System
Fuel System
About Fuel System
The in-line high-pressure gas filter needs to be changed on a regular basis. The timeframe between changes varies based on fuel type, quality and site specifications. It is recommended that the filter be inspected monthly.
Material List (Customer Supplied Parts)
Keep the following items on hand when conducting maintenance on the fuel system: Gas filter O-Ring for gas filter
How to Change HighPressure Gas Filter
Follow the procedures below to change the high-pressure gas filter. High-pressure flammable gas! No smoking, no open flames, no sparks or ignition sources shall be present. Step 1 2 3 4 5 6 7 8 9 10 Action Gather necessary materials (see Material List, page 60) Shut off gas by activating customer-provided high-pressure emergency gas shut-off valve Release line pressure using plant-approved safety procedures Remove top of gas filter high-pressure vessel Remove o-ring Remove gas filter and dispose of using approved local, state and federal procedures Lift off any plate or cap sealing the element end and remove the element Clean pressure vessel and dispose of waste using approved local, state and federal procedures Reverse this procedure to install new element Always re-pressurize the filter housing by slowly opening the inlet valve first. Then when the housing has come to pressure, open the outlet valve to allow flow to pass through. Constantly check for leaks in filter housing using plant-approved safety procedures; (for example, use a soap/water solution) and correct any leaks prior to starting engine.
Leaks are explosive!
Fuel System 57
Fuel System, Continued
Images
Below are pictures of the fuel filter.
Figure 27, Fuel Filter
Fuel Filter
58 Fuel System
Air System
Overview
Customer may supply the air filter based on site-specific installation. See specific air filter manufacturer instructions/recommendations for maintenance. Air filters are site-specific and supplied through various manufacturers and contractors. See specifications for each.
Air System 59
Battery Maintenance
About Battery Maintenance
The batteries in the generator set are lead acid batteries and require maintenance on a regular basis. Monthly maintenance is recommended, except for testing of the specific gravity of the electrolyte, which is recommended every 12 months. Take safety precautions when handling lead acid batteries. Do not stand over battery. Wear approved safety apparel including safety glasses, face shield and approved apron. Follow all local, state and federal procedures.
Material List (Customer Supplied)
Keep the following items on hand when conducting battery maintenance: Approved liquid (example: De-ionized or distilled water) Battery specific gravity tester or hydrometer Wire brush for cleaning battery tops and terminals Portable eyewash station
Predictive Maintenance
Every month inspect and clean battery tops, check liquid levels, and inspect connectors for tightness and corrosion. Every 12 months, test the specific gravity of the electrolyte. Replace battery if battery fails the test.
Image
Below is a picture of the batteries in the generator set.
Battery Caps (multiple)
Figure 28, Batteries in Generator Set Continued on next page
60 Battery Maintenance
Battery Maintenance, Continued
How to Check Battery Levels
Follow the procedures below and manufacturers recommendations to check battery levels. Step 1 Action Remove battery caps Check if liquid is at acceptable indicated levels (bottom of filler neck) If Yes No Repeat for each battery Then Replace caps Go to How to Refill Batteries; page 61
How to Refill Batteries
Follow the step-by-step procedures below and manufacturers recommendations to refill batteries. Step 1 2 3 4 5 Action Gather necessary materials (see Material List, page 60) Remove battery caps Fill battery with approved liquid to indicated levels (bottom of filler neck) Replace battery caps Repeat for each battery
How to Clean Batteries
Follow the step-by-step procedures below and manufacturers recommendations to clean batteries. Step 1 Action Gather necessary materials (see Material List, page 60) Check battery tops and caps for corrosion If Then Corroded Use wire brush to remove corrosion Not Corroded Go to step 3 Repeat for each battery
Battery Maintenance 61
Battery Maintenance, Continued
How to Test Specific Gravity of Battery
Follow the procedures on battery tester or hydrometer and below. Battery tester or hydrometer may be available from an auto parts supplier. Step 1 2 3 Action Gather necessary materials (see Material List, page 60) Follow instruction on tester to draw battery fluid into tester Read instructions on tester to observe cell condition. Read indicated level If Within acceptable limits Outside of acceptable limits Then Completed, go to step 5 Recharge battery, go to step 4
Follow instructions below for recharged battery. If recharged battery is Within acceptable limits Outside of acceptable limits Then Completed, go to step 5 Replace battery, go to step 5
Repeat process for each battery starting at step 2
62 Battery Maintenance
Engine Compressor Section
About Engine Compressor Water Wash Material List (Customer Supplied Parts)
For increased efficiency, an engine compressor water wash is recommended every 300 hours of operation or as needed based on operating conditions.
Keep the following items on hand when conducting maintenance on the Engine Compressor. Pressurized Water Wash header
Water Wash Procedure
Follow the steps below to complete the engine compressor water wash procedure.
Step 1 2 3 4 5 6
Action Install wash header in compressor air inlet Hook up pressurized water source, with 10 lb of pressure, to wash header (a commercial pump up garden sprayer is sufficient) Lock out and valve out fuel supply. Crank engine with starter motor for 2 minutes with water sprays in operation Shut Off water supply and stop cranking engine Remove water supply and wash header Start engine and run for at least 5 minutes to dry out engine terminals. Check for unusual noises or vibration
Engine Compressor Section 63
Major Maintenance Schedule
Schedule
The generator set major maintenance schedule is listed below. Components Maintenance Item Battery Clean battery tops, check liquid level and inspection connections for corrosion; top off cells with distilled water when low, see Battery Maintenance, page 60 Test the specific gravity of the electrolyte. Replace battery if battery fails test, see Battery Maintenance, page 60 Inspect the drive belt and replace if Battery worn or cracked Charging Alternator, Black Start Equipped Machines Computer Clean or replace air filters as required Inspect isolation mounting hardware for deterioration, replace as necessary Engine Wash turbine compressor, see Engine Compressor Section, page 63 Perform hot section inspection by manufacturers authorized personnel Recommended engine replacement Change oil, see Oil System, page 50 and Appendix B, page 77 Gearbox Inspect bearings and replace as needed. see Appendix B, page 77 Change oil, see Oil System, page 50 and Appendix B, page 77 Schedule Every month
Every 12 months
8,000 hours or 12 months
6 months 12 months 300 hours of operation 8,000 hours of operation 30,000 hours of operation 10,000 hours or every 18 months 10,000 hours of operation First 350 hours of operation, then every 2,500 hours of operation or 6 months, whichever comes first 40,000 hours of operation
Generator
Oil Coolers
Inspect bearings and replace as necessary, see Appendix B, page 77 Grease bearings if generator is 5,000 hours or 12 months provided with grease fittings, see Appendix B, page 77 Inspect cooling fans for dirt and debris. 6 months Use compressed air to blow dirt out of the fan area when needed
64 Major Maintenance Schedule
Heavy Maintenance
Heavy Maintenance
It is recommended that only qualified personnel perform heavy maintenance. Provided by assembler AEP Gas Power Systems authorized service shops and/or personnel Qualifying training available on request
Heavy Maintenance 65
Maintenance Parts
Recommended Parts List
Introduction
The following is a list of recommended maintenance parts.
Parts List
The recommended parts list is included below for your convenience. Also see Appendix A, page 75. Not all brands of oil are compatible with each other. Name Oil (Engine and Gearbox) Part Number MIL-L-23699 Recommended Manufacturer Shell Oil Company AeroShell 500 Turbine Oil Norman Filter Company
Oil Filter (includes one part #603M 3 micron microglass filter cartridge with a viton seal Fuel Filter O-Ring for Fuel (Gas) Filter Grease for Generator Bearings Modules
520P-15-0-0-603M-N
Housing F2-275F Element 2015K5 52939P001 Asonic GHY72 #611235 Art. # 094049 (1) Digital Input # 70G-IDC5 (2) Digital Outputs # 70G-0DC5MA (2) Analog Inputs # 73G-11420 (1) Analog Output # 73G-0V10B (1) RTD # 73G-ITR100 Cat.# 108051.00 Model # C4D17NK10C Haight 1-8 D/DR Haight 10-40 D/DR 199901G0CF
FilterFab Manufacturing FilterFab Manufacturing Kluber Lubrication Garyhill Corporation
Pump Motors Pumps Fan Motors
Leeson Electric Corporation Baker Manufacturing Company SPAL of Italy
Recommended Parts List 67
Troubleshooting
General Topics
Troubleshooting Topics
A number of general topics are identified in the table below including probable causes and remedies. Symptom Alarms/responses Probable Cause Various Remedy Clear alarms and restart to see if alarm repeats Call up alarm screen on computer to determine first alarm to activate Follow with maintenance to alarm cause Restart and repeat if another alarm activates Clean corroded battery by using a safe and approved agent Recharge or replace battery Add appropriate fluids to recommended levels Check power to 5v power supply and check fuse on back board (top right hand corner) 70GRCP32 Check external wiring for connection and replace module on affected channel with serviceable module Check the following: Computer power sources for loose connection, Computer screen for error messages For loose cards reseat cards; Contact AEP GPS for assistance
Battery corroded Battery fails specific gravity test Battery water levels low Blinking B on all program channels Blinking B on one program channel Computer wont boot
Moisture and dirt accumulated on top battery top Discharged battery High temperatures Power supply
Channel not functioning
Power supply; loose cards
General Topics 69
General Topics, Continued

Troubleshooting Topics (continued) Symptom Control malfunctions Probable Cause Failed sending unit Remedy Check hardware inputs for proper signals; if signals are okay, call AEP GPS for assistance Contact AEP Gas Power System or authorized agent for paint type Add oil to recommended level, check for leaking and repair Check fuel system for correct pressure and unobstructed flow, check electrical system Check the following: Starter battery voltage For N1 indication upon starter engagement (N1 speed should increase when starter engages) Fuel pressure Cycle fuel valve (by pulling cannon plug off valve and replacing) If maximum N1 obtained maximum EGT, maximum fuel valve opening then call AEP GPS for assistance Repair insulation
Cracks/rust/peeling paint/corrosion Engine oil below recommended level Engine stops
Paint chipped or worn Possible oil leak No fuel, no electric
Engine wont start
No electric or no fuel
Frayed wires
Animals chewing wires
70 General Topics

Troubleshooting Topics (continued) Symptom High/low lube oil pressure Probable Cause Failed pressure sensor, low oil level Remedy Low Check oil levels and add if necessary, installed gauge on inlet oil pressure line to verify pressure High Install gauge to verify pressure, check pump pressure relief valve for proper operation, check engine inlet oil screen and clean High Check for proper level in oil tank, check for cooling pump operation, check radiator fans and air flow to radiators for restrictions Low Allow engine to warm up Utility interconnection mode Check grid voltages Isolated mode Check AVR for proper setting; can adjust voltage by AVR or replace AVR if necessary Determine frequency of vibration to determine if cause is on generator end or the engine end of the unit; Call AEP GPS for assistance Check bearing temperature with another sources to verify sending unit is working properly; rotate shaft and listen for excessive noise, check oil temperature and pressure
High/low lube oil temperature
Low oil, oil cooling system
High/low output voltage
Utility interconnection mode Gird voltage most likely high/low Isolated mode Difficulty with automatic voltage control (AVR) MIS alignment
High vibration
High bearing temperature
Temperature pickup failure
General Topics 71

Troubleshooting Topics (continued) Symptom High exhaust gas temperature Probable Cause Inlet air blockage Remedy Check inlet air filters for blockage or dirt, replace or clean; Check for restriction in inlet air duct; Check to see if exhaust is entrained in inlet air, heat rejected from another source is taken into inlet of engine Inspect inlets to generator cooling air and remove blockage Replace hoses, tighten plumbing joints Check fuel filter for dirt and blockage, replace or clean; if using gas compressor - check for proper fuel outlet pressures; if pipeline supply check for proper delivery pressure and call supplier; if liquid system check for blockage in fuel line Check electric output breaker to verify it is closed, verify load.
High generator winding temperature Leak in plumbing/hoses Low fuel pressure
Generator cooling air blockage Wear, loose joints Blockage in fuel system; improper supply
Low kW output
Breaker
72 General Topics

Troubleshooting Topics (continued) Symptom No A/C power Oil cooling system fails (oil not flowing) Oil filter leaking Two power lights are not illuminated on the upper and lower back boards Probable Cause Power cables Pump motor, fan motor failed Gasket failure, defective or loose filter, possible puncture Power supply; computer card Remedy Check power supply cord and check GFI trip-reset Contact AEP Gas Power System or authorized agent Tighten or install new oil filter Check 5 volt logic power; If red lights arent on call AEP GPS for assistance
General Topics 73
Appendix A
Manufacturer Information List
Introduction
The manufacturer contact information list below is provided for your convenience.
FilterFab Manufacturing 3709 Greengarden Road Aliquippa, PA 15001 Phone: (724) 375-6927 (800) 899-6927 Kluber Lubrication See website, www.kluberna.com for local distributor Norman Filter Company 9850 South Industrial Drive Bridgeview, IL 60455 Phone: (708) 430-4000 (800) 207-6045 Shell Oil Company (local distributor)
Manufacturer Information List 75
Appendix B
Manufacturer Reference Manuals
Overview
This section provides you with manufacturer reference manuals for your use. See topic to determine which manufacturer material may be of interest. Topic Batteries Gearbox Generator Motor Oil Pumps Fuel Valve Manufacturer Trojan Battery Company / Exide Corporation Cotta Transmission Company Newage International Limited Leeson Electric Corporation Baker Manufacturing Company Continental Controls Corporation See Attachment B-1 B-2 B-3 B-4 B-5 B-6
Manufacturer Reference Manuals 77
Appendix C
Material Safety Data Sheets
MSDS
This Appendix contains Material Safety Data Sheets. Reference the table below for the MSDS of interest. MSDS # 857490E-01 9140002474363 614000F036165 CSW7000101 Description Aeroshell Turbine Oil 500 Fuel Oil #2 (Diesel fuel) Lead-Acid Battery Natural Gas See Attachment C-1 C-2 C-3 C-4
Material Safety Data Sheets 79
Appendix D
Drawings
Innovator Drawings
This Appendix includes drawings for the Innovator generator set. Reference the table below for the drawing of interest. Description Genset Steel Outline Drawing Number S-1001
Drawings 81
Copyright by AEP, 2001. All rights reserved.

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Generator Set Manual

AEP Gas Power Systems Innovator Generator Set

(Picture from Corp. Comm.)

AEP Gas Power Systems

AEP Gas Power Systems

AEP Gas Power Systems

AEP Gas Power Systems

This chapter contains the following topics: Topic See Page 3 5 7 8 9 10

AEP Gas Power Systems

AEP Gas Power Systems

Innovator Diagram, Continued

Part Identification Legend

AEP Gas Power Systems

Below is a photograph of the engine.

Exhaust area will have high temperatures and airflow.

Continued on next page

AEP Gas Power Systems

Fuel (gas) System

AEP Gas Power Systems

About the Gearbox

Below is a picture of the gearbox.

AEP Gas Power Systems

About the Generator

Below is a picture of the generator.

AEP Gas Power Systems

About the Control System

Below is a picture of one screen of the control system.

Figure 6, Screen of Control System

AEP Gas Power Systems

Innovator Features and Spec Sheet

Below is a picture of the Innovator generator set.

Figure 7, Innovator Generator Set

10 Innovator Features and Spec Sheet

AEP Gas Power Systems

Innovator Features and Spec Sheet, Continued

AEP Gas Power Systems

Innovator Features and Spec Sheet 11

Innovator Features and Spec Sheet, Continued

Continued on next page

12 Innovator Features and Spec Sheet

AEP Gas Power Systems

Innovator Features and Spec Sheet, Continued

Nominal Performance Ratings

Optional Equipment and Services

Part Generator Options

Lube Oil System

Accessory Equipment Enclosure

AEP Gas Power Systems

Innovator Features and Spec Sheet 13

Innovator Features and Spec Sheet, Continued

14 Innovator Features and Spec Sheet

AEP Gas Power Systems

AEP Gas Power Systems

AEP Gas Power Systems

AEP Gas Power Systems

Receiving and Handling

Receiving the Generator Set

Handling the Generator Set

Continued on next page

18 Receiving and Handling

AEP Gas Power Systems

Receiving and Handling, Continued

AEP Gas Power Systems