P9005manu Gas Turbine

P9005_8 – Cussons Technology – Two Shaft Gas Turbine Page 1 of 232
P9005
CUSSONS TWO SHAFT GAS
TURBINE UNIT
P9008
DATA LOGGING OPTION
ISSUE 15
January, 2004
cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

—TECHNOLOGY Ltd— Phone +44 161 833 0036 email sales@cussons.co.uk
TABLE OF CONTENTS
1 RECEIPT AND UNPACKING ......................................................................................6
2 HEALTH AND SAFETY WARNINGS AND PRECAUTIONS ........................................... 7

2.1 Manufacturers Liability. ..................................................................................... 7
2.2 Safety.................................................................................................................. 7
2.2.1 Electrical Equipment. ........................................................................................ 8
2.2.2 Rotating Equipment. ......................................................................................... 8
2.2.3 High Temperature Equipment............................................................................ 8
2.2.4 Corrosive Chemicals.......................................................................................... 9
2.2.5 Noise............................................................................................................... 9
3 INTRODUCTION......................................................................................................10
4 GENERAL SPECIFICATION .....................................................................................11

4.1 General..............................................................................................................11
4.2 Gas Generator...................................................................................................11
4.3 Power Turbine. .................................................................................................11
4.4 Loading Alternator with Silicon Diode Rectifying Circuit................................11
4.5 Instrumentation. ..............................................................................................11
4.5.1 Pressure Measurement.................................................................................... 11
4.5.2 Flow Measurement. ........................................................................................ 11
4.5.3 Temperature Measurement. ............................................................................ 12
4.5.4 Speed Indicators. ........................................................................................... 12
4.5.5 dc Measurement............................................................................................. 12
5 DESCRIPTION.........................................................................................................13
5.1 General..............................................................................................................13
5.2 Gas Generator...................................................................................................13
5.2.1 Compressor. .................................................................................................. 13
5.2.2 Combustion Chamber. .................................................................................... 13
5.2.3 Turbine. ........................................................................................................ 13
5.3 Power Turbine. .................................................................................................14
5.4 Loading System for Power Turbine..................................................................14
5.5 Starting System. ...............................................................................................14
5.6 Ignition System. ...............................................................................................14
5.7 Lubrication System...........................................................................................14
5.8 Instrumentation. ..............................................................................................15
5.8.1 Temperature.................................................................................................. 15

5.8.2 Pressure. ....................................................................................................... 15

5.8.3 Air Flow Rate. ................................................................................................ 15
5.8.4 Fuel Flow Rate. .............................................................................................. 16
5.8.5 Rotational Speeds........................................................................................... 16
5.8.6 Power Output................................................................................................. 16
5.9 Operational Interlocks. ....................................................................................16
5.9.1 Turbine Over Temperature.............................................................................. 17
5.9.2 Loss of Oil Pressure. ....................................................................................... 17
5.9.3 Starter Blower Motor. ..................................................................................... 17
5.9.4 Oil Pump Motor. ............................................................................................. 17
5.9.5 Electrical Power Failure. .................................................................................. 17
5.10 Signal Conditioning for Data Logging (P9008 optional extra). ...................17
6 INSTALLATION, COMMISSIONING, CALIBRATION AND MAINTENANCE.............19

6.1 Installation. ......................................................................................................19
6.1.1 Electrical Supply. ............................................................................................ 19
6.1.2 Fuel Supply.................................................................................................... 19
6.1.3 Water Supply. ................................................................................................ 19
6.1.4 Exhaust Provisions.......................................................................................... 19
6.1.5 Lubrication System. ........................................................................................ 19
6.1.6 Air Flow Manometer........................................................................................ 20
6.1.7 P2 - P3 Manometer......................................................................................... 20
6.2 Commissioning. ................................................................................................20
6.3 Calibration. .......................................................................................................20
6.3.1 Speed Measurement. ...................................................................................... 20
6.3.2 Temperature Measurement. ............................................................................ 20
6.3.3 Turbine Inlet Temperature - Over Temperature Trip.......................................... 23
6.4 Maintenance. ....................................................................................................23
6.5 Additional Calibration Procedure for P9008 Option........................................23
6.5.1 Preparatory Work. .......................................................................................... 24
6.5.2 Fuel Flow....................................................................................................... 24
6.5.3 Air Flow......................................................................................................... 24
6.5.4 Alternator Voltage. ......................................................................................... 24
6.5.5 Alternator Current. ......................................................................................... 24
7 OPERATING INSTRUCTIONS.................................................................................. 25
7.1 General..............................................................................................................25
7.2 Starting. ............................................................................................................25

7.3 Operating Limitations.......................................................................................25

7.4 Stopping............................................................................................................26
7.5 Notes on Operating Instructions. ....................................................................26
7.5.1 Starting. ........................................................................................................ 26
7.5.2 Operation. ..................................................................................................... 26
7.5.3 Stopping........................................................................................................ 27
8 APPENDIX I – A FIRST COURSE IN GAS TURBINE TECHNOLOGY ........................47
9 APPENDIX II – POWER TURBINE ........................................................................115
10 APPENDIX III – GAS GENERATOR ....................................................................170
11 APPENDIX IV – LOADING UNIT ........................................................................222

ILLUSTRATIONS AND GRAPHS

Figure 1 Front Panel Layout of Gas Turbine Unit
Figure 2 Rear View of Gas Turbine Unit
Figure 3 Electrical Component Layout on Control Panel
Figure 4 Inner Combustion Chamber
Figure 5 AC 7 Alternator Calibration
Figure 6 Lubrication System
Figure 7 Gas Generator Compressor Characteristics
Figure 8 Gas Generator Turbine Characteristics
Figure 9 Free Power Turbine Characteristics
Figure 10 Printed Circuit Board CBA 216 (Speed)
Figure 11 P9005 Gas Turbine Test Sheet
Figure 12 Correction Factor Curves for Fuel Flowmeter
Figure 13 Installation Details
Figure 14 Printed Circuit Board CBA 219 (Temperatures)
Figure 15 Printed Circuit Board CBA 220 (Analogue Computing) Optional Extra
Figure 16 Overall Schematic Diagram
APPENDICES
App. I A First Course In Gas Turbine Technology – T.H. Frost
Section 1 Fundamental Concepts
Section 2 Types and Arrangements of Engine Components
Section 3 Test Techniques
Section 4 A Complete Test and Analysis Programme
App. II Power Turbine
App. III Gas Generator
App. IV Loading Unit

1 RECEIPT AND UNPACKING

Irrespective of who has arranged the carriage and insurance of the goods, the carriers and insurers
require that claims for loss of damage are submitted within a specified period after receipt of the
goods. This period is often as short as 72 hours. It is important therefore for the customer to carry
out the following procedure as soon as the equipment is received.
a) On receipt, the goods should be signed for “unexamined”.
b) Immediately unpack and check the equipment against the dispatch checklist / packing lists
enclosed with the equipment.
c) Advise the carrier within 72 hours of receipt, of any damaged or missing items, holding
them responsible for the damage or loss. A copy of this advice document must also be
sent to Cussons Technology Ltd.
d) If you have arranged insurance you must advise your insurers of the damage/loss
enclosing a copy of the advice document that you have submitted to the carrier.
e) If Cussons Technology Ltd. arranged insurance, you must advise the local agent at the
address indicated on the original Insurance Certificate in your possession. A copy of this
advice document must also be sent to Cussons Technology Ltd.
You should retain all evidence of loss or damage. Claims for loss or damage cannot be
entertained if the above procedures are not adhered to.

2 HEALTH AND SAFETY WARNINGS AND PRECAUTIONS
2.1 Manufacturers Liability.

Cussons Technology Ltd. hereby draws the attention of all users of its equipment to the UK.
Health and Safety at Work Act, or of any similar provisions relating to health and safety of
people at work in other countries and territories, which refer to the liability of manufacturers or
suppliers of equipment.
Under the U.K. Act manufacturers or suppliers of equipment cannot be liable for the consequence
of its use unless it is installed, maintained and operated strictly in accordance with the
instructions published by the manufacturers or suppliers. This same limit of liability is hereby
assumed by Cussons Technology Ltd. to be valid in all countries or territories.
Therefore Cussons Technology Ltd will not be liable for any consequence of failure to heed
warnings and precautions, improper installation or maintenance, improper use or incorrect
operation of equipment, unless specifically authorised in writing by the Company in advance of
their implementation, will invalidate equipment warranty and absolve Cussons Technology Ltd
from liability.
Cussons Technology Ltd. recognises the need for equipment to be safe to operate and to be fit for
the purpose for which it is designed. The Company pays considerable attention to these aspects
and designs and manufacturers equipment to the highest safety standards with highly visible
quality assurance.
Where applicable Cussons products incorporate the CE Mark indicating that the product
conforms to relevant EU “New Approach” Directives. Compliance with these requirements can
only be assured when the equipment has been properly installed and maintained within the
intended environment. It is particularly important that all guards, covers, doors and other
protective or screening devices are correctly fitted whilst products are operated. Typically
Cussons products are designed for operation in applications designated under the directives as an
“industrial environment”. Users intending to install or operate equipment in other environments
should seek specific advice concerning additional or alternative measures that should be
considered.
Any customers requiring further advice on safety aspects concerning installation, and use of
Cussons equipment should write to the company at the following address giving full details of the
equipment, it’s serial number and the exact details of their enquiry:
Cussons Technology Ltd

102 Great Clowes Street,
Manchester, M7 1RH, U.K.
Telephone +44 (0)161 833 0036

Facsimile +44 (0)161 834 4688
Email: sales@cussons.co.uk
2.2 Safety.
Before proceeding to install, commission or operate this equipment you are directed to read the
following safety notes. The notes are intended to help you to be aware of potential hazards and

thereby avoid accidents. Where appropriate, further information and recommendations are
incorporated in the main body of this manual. In all cases the requirements of relevant local
health and safety regulations should be complied with.
2.2.1 Electrical Equipment.
This equipment operates from a mains voltage electrical supply. Electrical installation
and maintenance must therefore only be carried out by a competent electrical engineer in
accordance with local regulations and the following notes.
a) Installation.
Ensure that the electrical supply voltage, frequency and configuration are compatible
with this equipment, which requires a single/three phase supply and a reliable protective
earth or ground connection.
To minimise danger, as the supply is connected by a trailing lead**, it is recommended
that a high sensitivity (30mA) residual current device which is designed for personnel
protection, should be incorporated in the supply.
The electrical supply and connecting cable should be suitably rated with respect to
current, temperature and physical protection for the conditions of use. The supply outlet
should be suitably labelled and must incorporate an independent means of isolating the
supply and be fitted with a suitable over-current protection device.
b) Maintenance.
Always isolate the equipment from the electrical supply when the equipment is not in
use.
Always isolate the equipment from the electrical supply before removing the front or
rear panels to expose any part that in operation, carries a potential in excess of 30V dc.
or 50V ac.
The equipment should be periodically inspected and tested to ensure continued safety.
2.2.2 Rotating Equipment.
This equipment contains rotating parts, which rotate at very high rotational speeds. The
equipment is provided with guards and the equipment must therefore only be operated
with the guards in position. If for any reason the guards are removed then there is a
serious risk of the rotating parts causing the entrapment of loose clothing, hair, items of
jewellery or parts of the body etc. Consequently the equipment must not be operated
without the guards being properly fitted.
2.2.3 High Temperature Equipment
During operation this equipment contains parts and water/air at high temperature. To
minimise associated hazards the following precautions must be taken:
a) The equipment must be installed and maintained by a competent engineer in
accordance with local regulations and codes of practice.
b) Before operating read and understand the instructions given. Avoid the dangerous
release of hot fluids, e.g. by opening the wrong valves. Leakage’s from valves and
joints should be investigated and rectified as soon as possible.
c) Avoid contact with hot surfaces as serious burns can result. If necessary the
operator should wear protective gloves.

d) The equipment must be subject to periodic inspection and testing to ensure

continued suitability for use. This should include as applicable:
i) The Integrity of all vessels, containers, pipe work, and valves
ii) The integrity of all guards and insulation
iii) The operation of safety devices such as thermostats
e) Implement any instructions that are designed to minimise corrosion or other
deterioration including the proper treatment of boiler feed water and condenser
cooling water.
2.2.4 Corrosive Chemicals.
When used for pH control experiments this equipment requires the use of dilute aqueous
solutions of corrosive chemicals. The equipment is designed for use with dilute
sulphuric acid up to a concentration of 1M (2N) and dilute sodium hydroxide up to a
concentration of 1M (1N). Use of these chemicals at stronger concentrations can not be
recommended and is not approved by Cussons Technology Ltd., similarly the equipment
is not intended for use with other chemicals. In practice satisfactory results can be
obtained with using 0•05M sulphuric acid and 0•01M sodium hydroxide as the strongest
solutions and diluting them down by factors of 10, 100 and a 1000 to obtain weaker
solutions. Data sheets on the handling of dilute sulphuric acid solutions and dilute
sodium hydroxide solutions are given in Appendix 1.
2.2.5 Noise.
Wearing ear defenders is recommended in noisy environment in excess of 85 dBa.

3 INTRODUCTION
The P9005 Cussons Gas Turbine Unit is a full two shaft machine with built in air starting system
and electrical loading unit. All operational instrumentation and controls are to be found on the
large coloured schematic diagram panel mounted at a convenient operating height. Light
indicators and clear reading instruments enable the operator to be aware of circuit conditions at a
glance.
The equipment employs an automotive turbocharger together with a gaseous fuelled combustion
chamber to form the gas generator section of the engine. The exhaust from the gas generator is
directed through a radial power turbine which drives a variable frequency alternator which
disipates the generated power in a resistive load bank. From the power turbine the gases pass
through a silencer to be discharged into the atmosphere.
Since the unit is mobile it can easily be sited adjacent to its required electrical, fuel, water and
exhaust facilities, and even when operating at high speed it has only a relatively low noise level.
Signal conditioning for data logging purposes can be provided as an optional extra by the factory
fitted P9008 Data Logging Option available from serial number 206 onwards. The P9008 option
provides 0-10V dc analogue signals for all measured parameters.

4 GENERAL SPECIFICATION
4.1 General.
Note that from Serial No. 167 onwards, the Gas Turbine Unit has been tropicalised and is
generally suitable for use in ambient temperatures of up to 40ºC and ambient conditions of up to
80% relative humidity.
4.2 Gas Generator.

The gas generator consists of a single stage centrifugal compressor, a single gaseous fuelled
combustion chamber and a single stage radial turbine. The compressor and turbine are mounted
back to back on a short shaft supported in a journal bearing. The compressor impellor has a tip
diameter of 72mm whilst the radial turbine has a throat area of 16cm² and a tip diameter of
70mm. The gas generator operates at a pressure ratio of approximately 2:1 and speed range of
500 to 2000 rev/sec.
The combustion chamber and the associated instrumentation are designed for use with propane
C3H8 but may be used with a mixture of propane and butane C4H10 provided that the pressure in
the supply bottle is sufficient to inject the fuel into the combustion chamber.
4.3 Power Turbine.

90mm diameter, single stage radial turbine operating over the range 170 to 600 rps and
developing a maximum power of approximately 4 kW.
4.4 Loading Alternator with Silicon Diode Rectifying Circuit.

3 phase alternator with manually controlled excitation supplying a 3 phase bridge rectifier circuit
giving a variable dc output of up to 75 volts with a current rating of up to 35 amps
(approximately).
4.5 Instrumentation.
4.5.1 Pressure Measurement.
0 – 1600 KPa (0 – 16 bar) Gas Bottle supply indicator
0 – 400 KPa (0 – 4 bar) Combustion chamber inlet gas pressure
0 – 250 KPa (0 – 2 bar) Combustion chamber pressure p3
0 – 40 KPa (0 – 0.4 bar) Power Turbine inlet pressure p4
0 – 10 cmHg Combustion chamber pressure loss p2 - p3
(p2 is compressor outlet pressure)
0 – 1000 KPa (0 – 10 bar) Lubricating oil pressure
4.5.2 Flow Measurement.
0.4 – 3.3 g/s Fuel flow (propane 15°C, 1.5 bar g)
0 – 200 mmH2O Inlet air flow

4.5.3 Temperature Measurement.

All temperatures are measured using NiCr/NiAl type K thermocouples
0 – (16 x 10)°C Inlet air temperature T1
Compressor outlet temperature T2
Fuel inlet temperature Tg
0 – (10 x 100)°C to measure :
Gas generator turbine inlet temperature T3
Power turbine inlet temperature T4
Power turbine exhaust temperature T5
0 – 40/120°C to measure :
Lubricating oil temperature T0
4.5.4 Speed Indicators.
0 – 2000 rps Gas generator speed
0 – 800 rps Power turbine speed
The tachometers are electronic, direct reading.
4.5.5 dc Measurement.
Mean dc ammeter 0 – 50 amps
de Voltmeter 0 – 100 volts

5 DESCRIPTION
5.1 General.
Cussons P9005 Two Shaft Gas Turbine Unit is a self contained equipment with the gas generator,
power turbine, loading unit, instrumentation and controls all housed on a castor mounted
framework, giving a degree of mobility. Thus the Unit can be tidily stored when not in use and
then readily positioned near the required services, when it is required to be run. The services
required are :
a) The Unit requires to be positioned under an exhaust duct so that the gas turbine exhaust
products can be extracted if prolonged running is contemplated.
b) A cooling water supply is required for the oil cooler.
c) A drain is required to cater for the oil cooling water.
d) A single phase electrical power supply.
e) A suitable gaseous fuel supply.
The instrumentation and controls for the Unit are incorporated in a large coloured schematic
diagram of the system - see Fig. 1 Front Panel Layout of Gas Turbine Unit. This diagram is
invaluable as an aid to understanding the complete functioning of the Gas Turbine Unit. Fig. 2
Rear View of Gas Turbine Unit illustrates the physical disposition of all the major components.
5.2 Gas Generator.

The single shaft gas generator comprises a centrifugal compressor, a tubular combustion chamber
and a radial turbine (Fig. 2, Refs. B, C and D). The compressor and gas generator turbine are
close coupled with the shaft located in a central housing by hydrodynamic bearings (see
Appendix 2 for further details).
5.2.1 Compressor.
The compressor is a single sided centrifugal type with a multi-bladed aluminium alloy impeller,
and an unbladed diffuser volute casing with tangential exit.
5.2.2 Combustion Chamber.
The single vertical combustion chamber is of conventional design, incorporating a flame tube
with central fuel injector for gaseous fuels. The combustion chamber is shown in Fig. 4 Inner
Combustion Chamber. The flame tube divides the incoming air flow into ‘primary’ and
‘secondary’ air, with a stabilised combustion zone and tertiary dilution air. A spark igniter is
mounted in the side of the combustion chamber for starting purposes. To allow a compressor air
bleed to be taken from the chamber an air valve is incorporated in the top of the combustion
chamber outer casing.
5.2.3 Turbine.
The gas generator turbine is a single inward flow radial design with a volute type inlet casing.

5.3 Power Turbine.

The power turbine is also, as with the gas generator, based on an automotive turbocharger, but in
this case the compressor has been replaced with a toothed pinion to provide a belt drive to the
electric generator unit (see Appendix I for further details).
5.4 Loading System for Power Turbine.

The power turbine drives a separately excited 3 phase alternator via a toothed belt having a 4½ to
1 speed reduction. The alternator incorporates an internal 3 phase bridge rectifying circuit which
gives a dc output of 75 volts. The tension of the toothed driving belt is automatically controlled
by the hydraulic ram (Fig. 6 Lubrication System), which is fed from the lubricating oil system.
The dc output of the rectifying circuit is resistively loaded - thus imposing a load on the alternator
and hence the driving turbine. The output voltage of the alternator can be varied by adjustment of
the excitation voltage applied to the alternator field coils. This causes the power loading on the
alternator (and hence the turbine) to be easily variable over the required operating range.
Readings of mean dc output voltage and current can be used to calculate the dc power loading
and using Fig. 5 AC 7 Alternator Calibration, an “Efficiency” figure which takes into account
drive, alternator, and rectifier circuit efficiencies can be determined. The power loading on the
turbine is then given by :
calculated dc power loading
% efficiency figure
5.5 Starting System.

The gas generator is started by blowing air from a centrifugal fan onto the compressor of the gas
generator. Two butterfly valves, ganged together and operated by a start-run control from the
front panel, are used to close off the normal air inlet silencer connection and direct air from the
fan onto the compressor. The fan is used throughout the starting sequence until self-sustaining
speed is reached. It is also used to obtain assisted cooling after shut down in order to reduce the
cool down time.
5.6 Ignition System.

A high energy ignition system is used to provide a continuous spark between the electrodes of a
conventional automotive sparking plug mounted on the combustion chamber casing and
positioned so that the electrodes are just inside the flame tube at the edge of the primary
combustion zone.
5.7 Lubrication System.

The gas generator compressor-turbine and the power turbine bearings are lubricated by a
continuous circulation lubricating system, which is shown schematically in Fig. 6. The system
comprises an oil tank, separately driven gear pump, oil filter and a water cooled oil cooler. The
pump draws oil from the tank and passes it through the full flow oil filter and oil cooler, directly
to the main bearings from which free flowing drain pipes lead back to the oil tank. The system is
protected by an oil pressure switch to shut down the gas turbine in the event of low oil pressure.
A small oil bleed from the main pressure supply pipe is taken to supply the belt tensioning
hydraulic ram. The recommended lubricant is Burmah Castrol “Assurnn T + 10” which is a low
viscosity monograde mineral based detergent oil with an anti-oxidant additive formulated for use

with turbocharged Diesel engines. The normal operating pressure of the lubrication system is 400
to 450 Kpa (4 – 4.5 bar) on starting from cold with the pressure dropping towards 200 Kpa (2
bar) as the working temperature in the oil tank rises. The oil cooler ensures that the temperature
of the oil fed to the bearings is maintained at approx. 80ºC.
5.8 Instrumentation.
Instrumentation for both operational and experimental measurement is integrated into the
coloured schematic diagram on the instrument and control panel.
5.8.1 Temperature.
From serial number 206 all seven temperatures are measured using type K NiCr/NiAl
thermocouples, whereas previous models used diodes for low temperatures and thermocouples
for high temperatures. The seven temperature channels are :
T1 Air inlet temperature
T2 Gas generator compressor exit temperature
T3 Gas generators turbine inlet temperature
T4 Power turbine inlet temperature
T5 Power turbine exit temperature
Tg Gas (fuel) temperature
To Oil (lubricant) temperature
All the thermocouples are connected via a cold junction compensation unit and break-out unit to
Cussons eight channel thermocouple printed circuit board CBA 219. For each channel there are
two independent outputs, one is for the front panel instrumentation while the other is a 0 - 10V dc
analogue output available for input to a data logger, computer input or chart recorder. Three front
panel analogue temperature indicators are provided. The three high temperatures T3, T4 and T5
are connected to a 1000°C meter, via cascaded push buttons to read T4 and T5. With neither
button depressed the meter reads T3. Similarly T1, T2 and Tg are connected to a 120°C meter
which normally reads T2 unless either the T1 or Tg button is pressed. The oil thermocouple is
permanently connected to the 120°C oil meter.
5.8.2 Pressure.
Conventional Bourdon tube pressure gauges are used to measure all pressures other than the
combustion chamber pressure loss (p2 – p3) which is obtained from a differential mercury
manometer. Snubbers are fitted in the P2, P3 and P4 pressure lines.
5.8.3 Air Flow Rate.
The air flow is measured at the inlet to the gas generator compressor by a pitot-reverse pitot tube
connected to a differential manometer on the front panel. The air mass flow rate is given by :
m& = k √∆h g/sec
where k = calibration constant (determined by Cussons and engraved on the unit)
∆h = differential pressure mmH2O
The pitot-reverse pitot method is used as it is not so sensitive as a pitot-static tube to flow pattern
distortion effects.

5.8.4 Fuel Flow Rate.

A conventional tapered tube and float flow meter calibrated for gaseous propane at 150 Kpa.g
(1.5 bar.g) and 15°C, is used to measure the fuel flow rate. Readings will need to be corrected for
other temperatures by using Fig. 12. If a butane-propane fuel mixture is used then the flow meter
readings can be corrected by multiplying by the square root of the quotient of the densities of
propane and the mixture of propane/butane, i.e.
 ρ propane 
m& mixture = m& reading  
 ρ mixture 
If the readings are taken at a pressure of 150 Kpa (1.5 bar) and a temperature of 15°C (which are
the calibration conditions for the flow meter) then the multiplicative correction factor is
 ρ propane   44 
  =  44Ρ + 58Β 
 ρ mixture   
where P = fraction of propane in mixture
B = fraction of butane in mixture
P B Correction Factor
1.0 0.0 1.000
0.9 0.1 0.984
0.8 0.2 0.970
0.7 0.3 0.955
0.6 0.4 0.942
0.5 0.5 0.929
0.4 0.6 0.916
0.3 0.7 0.904
0.2 0.8 0.893
0.1 0.9 0.882
0.0 1.0 0.871
5.8.5 Rotational Speeds.
The gas generator speed and free power turbine speed are both measured using two channels of a
four channel frequency to dc conversion printed circuit board CBA 216. The signal for the gas
generator is provided by an inductive pick up sensing a magnetic nut at the compressor eye,
whilst the power turbine speed is obtained by sensing the ac voltage output of the alternator.
5.8.6 Power Output.
The turbine power output can be calculated from the dc voltage applied and current flowing to the
resistive load bank, together with the curve Fig. 5 giving the relationship between dc power
measured and an efficiency factor which takes into account belt, alternator and rectifying circuit
efficiencies.
5.9 Operational Interlocks.

A number of operational interlocks or protection devices are built into the service systems to
ensure safe operation of the gas turbine. Pressing the RESET button will energise relay R1 and
hence make the fuel, ignition and starting systems operational. The RESET button is a

momentary switch which will self latch only if the interlocks associated with the oil pressure
switch, the over temperature cut-out and the starter blower motor thermal trip are correctly
positioned.
5.9.1 Turbine Over Temperature.
A comparator circuit contained within the eight channel temperature printed circuit board
continuously monitors the turbine inlet temperature T3. In the event of T3 exceeding the limit set
by the comparator circuit, relay R1 will be unlatched thus switching off the ignition system and
starting blower. The fuel shut-off solenoid valve will also be de-energised.
5.9.2 Loss of Oil Pressure.
An oil pressure switch monitors the pressure of the oil used to supply the oil circuit and if its
pressure falls too low the oil pressure switch opens and unlatches the relay R1, thus shutting
down the engine.
5.9.3 Starter Blower Motor.
The induction motor which drives the starter blower is protected by a thermal trip in the blower
motor contactor. Auxiliary contacts on the contactor are used to enable relay R1 thus providing
protection should the motor trip during operation.
5.9.4 Oil Pump Motor.
The induction motor which drives the oil pump is protected by a thermal trip in the oil pump
motor contactor.
5.9.5 Electrical Power Failure.
The system is designed to fail safe in that should electrical power be lost in any part of the
protection system or to the unit as a whole, then relay R1 will unlatch and the fuel solenoid valve
will close, thus causing the shut down of the equipment.
5.10 Signal Conditioning for Data Logging (P9008 optional extra).

Signal conditioning for Data Logging P9008 is an optional extra system which is only available
as a factory fitted option for P9005 systems from serial number 206 onwards. The P9008 option
comprises four pressure transducers, three differential pressure transducers, fuel orifice, rms
voltage and current sensing modules and an additional printed circuit board CBA 220, plus all
necessary additional wiring, piping and connections. The outputs, which are all amplified to
0 - 10V dc, unless otherwise stated, are connected to two D type sockets, as listed in the table
below.
Socket 1 9 Pin D Connector - Services Socket.
Pin Channel Description Mnemonic Range
1 0 Oil temperature To 0 - 200° C
2 Common Analogue ground - -
6 1 Oil pressure P 0 - 10 bar

Socket 2 25 pin D Connector - Analytical Socket.
Mne-
Pin Channel Description Range
monic
1 Common Analog ground - -

5 0 Air inlet temperature T1 0 - 50°C
6 8 Power turbine inlet pressure P4 0 - 400 mbar
7 9 Gas pressure Pg 0 - 4 bar
8 15 Fuel flow ∆Ρg 0 - 3.2 g/s
9 14 Gas generator speed Ngg 0 - 2000 rev/s
10 13 Turbine speed NPT 0 - 800 rev/s
11 12 Alternator current I 0 - 50 amps
12 11 Alternator volts V 0 - 100 volts
13 10 Air flow ∆Ρa 0 - 175 g/s
19 1 Compressor exit temperature T2 0 - 160°C
20 2 Gas generator inlet temperature T3 0 - 1000°C
21 7 Gas generator inlet pressure P3 0 - 2 bar
22 3 Power turbine inlet temperature T4 0 - 1000ºC
23 4 Power turbine exhaust temperatuer T5 0 - 1000°C
24 5 Gas temperature Tg 0 - 50°C
25 6 Combustion chamber pressure loss ∆Pcc 0 - 136 mbar
Apart from air flow and fuel flow the analogue outputs are all linear and correspond to the
appropriate front panel display.

6 INSTALLATION, COMMISSIONING, CALIBRATION

AND MAINTENANCE
6.1 Installation.
When the unit is required to be operational it should be wheeled into a position where all the
necessary ancillary requirements for electrical, fuel and water supplies, together with provisions
for the exhaust, are met. (See Fig. 13).
6.1.1 Electrical Supply.
A single phase ac supply of approximately 3.5 KVA is required for normal operation, e.g. 240V
50 Hz. Equipment may be supplied suitable for alternative supply specifications to order. Check
rating plate at rear of unit for correct supply specification. The blower motor, used for starting
purposes, can take initially high starting currents and hence the supply fuses should be such as to
cater for these transient starting conditions. A separate earth lead is also required.
6.1.2 Fuel Supply.
The fuel to be used is Propane (C3H8) a gas in standard gas take-off bottles for which suitable
fittings are provided. Short period running is possible from 11 kg (24 lb) net bottles but 45 kg
(100 lb) bottles are recommended for normal use. Providing that the ambient temperature is not
too low, one of these latter bottles will allow adequate operating periods at full power. Where it is
essential to site the propane bottles outside in cold conditions, it may be necessary to couple two
bottles in parallel to maintain an adequate supply. Consumption at full load is approximately 7 kg
(15 lb) per hour and at no load (idling) 2 kg (5 lb) per hour. Note that the level of liquid
remaining in the bottle during running can often be seen from the dew condensing on the outside
of the bottle, but for an accurate check on fuel available the bottle must be weighed by weighing
platform or spring balance.
6.1.3 Water Supply.
An oil to water heat exchanger is included in the oil circuit and the cooling water should be
connected to the at the inlet to the heat exchanger. The cooling water outlet should be connected
to waste. The water supply required should be made with a 9 mm (⅜") bore flexible hose and
have a minimum flow rate of 10 litres (2 gals) per minute.
6.1.4 Exhaust Provisions.
The exhaust is non-toxic and clean but for extended running, provision should be made for the
discharge to take place into a duct leading into the open air. However, there must be a break in
the exhaust system, usually in the form of a conical entry, with the turbine exhaust discharging
into the centre of the cone. This then ensures that the exhaust gas is diluted and reduces the
possibility of the final exhaust gas mixture being inflammable. Incorrect starting procedure can
produce inflammable exhaust mixtures and hence the above precautions should be taken.
6.1.5 Lubrication System.
The turbine’s lubricating oil is normally drained before shipment, it is therefore necessary to fill
the system with the CRH10 oil supplied.

6.1.6 Air Flow Manometer.

The air flow manometer has transit plugs fitted to prevent spillage of manometer fluid. Remove
these two rubber plugs and connect the two rubber tubes, 1 & 2, noting that their correct
orientation is required to measure the pressure differences.
6.1.7 P2 - P3 Manometer.
If the manometer has not been filled with mercury, then remove the two slot head screws from
the manometer top plate and fill through the back tube with approximately 35 grams of industrial
grade mercury. Ensure that all trapped air has been expelled before replacing the screw. Adjust
the zero reading by moving the scale plate to the appropriate position.
6.2 Commissioning.
It is important that the operator should familiarise himself with the operating procedure before
attempting to run the unit (see section 7).
6.3 Calibration.
6.3.1 Speed Measurement.
The speed measurement circuits on printed circuit board CBA 216 are calibrated prior to
dispatch, however, if necessary they can be adjusted without running the gas turbine as follows :
a) Preparatory Work.
Disconnect printed circuit board CBA 216 from its edge connector and re-connect it via a DIN
41612 64 way (rows a and c) extender card. Disconnect the two input co-axial cables from the
gas generator and power turbine by unplugging them at the rear of the control box.
b) Gas Generator.
Connect the output from a signal generator to the gas generator speed input socket on the rear of
the control box. Adjust the signal generator to produce a sine wave output of one volt peak to
peak at a frequency of 2000 Hz. Connect a digital voltmeter between test points TP8 and TP1 and
adjust VR10 to give a 10V output signal. Adjust VR11 to span the front panel gas generator
speed meter to 2000 rev/sec.
c) Power Turbine.
Connect the signal generator to the power turbine speed input socket on the rear of the control
box. Adjust the signal generator to produce a sine wave output of one volt peak to peak at a
frequency of 6400 Hz. Connect a digital voltmeter between test points TP4 and TP1 and adjust
VR3 to give a 10V output signal. Adjust VR4 to span the front panel gas generator speed meter to
800 rev/sec.
6.3.2 Temperature Measurement.
All the temperature channels are adjusted prior to dispatch and should not require further
attention. However, if any channel is found to need to be checked or adjusted the following
procedure, which refers to figure 14, should be followed.
a) Preparatory Work.
Disconnect the thermocouple plugs at the rear of the control cubicle. Open the hinge down lid of
the control cubicle and pull out the thermocouple printed circuit board CBA 219 from its edge
connector and re-connect it via a DIN 41612 64 way (rows a and c) extender card. A calibrated

millivolt source will be required to simulate the e.m.f. normally produced by the thermocouple
hot junction. A calibrated digital voltmeter will also be required.
b) Pre-amplifier Zero Adjustment.
Set jumpers J1 to J9 on the printed circuit board to position B and adjust the variable resistors, as
listed in column 2 of the following table, to give a reading of zero volts at the test points shown in
column 3 of the table with respect to test point TP1.
Channel Adjust Test Point
1 (T2) VR1 TP 3
2 (T1) VRS TP 5
3 (Tg) VR9 TP 7
4 (T3) VR13 TP 9
5 (T4) VR22 TP 11
6 (T5) VR26 TP 13
7 (TOil) VR30 TP 15
8 (spare) VR34 TP 17
Cold Junction VR17 TP 2
c) Pre-Amplifier Full Scale Adjustment.

Set jumpers J1 to J8 to position A. For each channel in turn connect the millivolt source to the
thermocouple socket shown in column 2 of the following table and inject the voltage shown in
column 3. Adjust the variable resistor listed in column 4 to obtain the voltage shown in column 5
at the test point listed in column 6 (relative to test point TP1).
T/C
Channel mV inject Adjust Reading Test Point
Socket
1 (T2) A 6.54 mV VR2 -1.6V TP 3
2 (T1) B 2.022 mV VR6 -0.5V TP 5
3 (Tg) C 2.022 mV VR10 -0.5V TP 7
4 (T3) D 41.27 mV VR14 -10V TP 9
5 (T4) E 41.27 mV VR23 -10V TP 11
6 (T5) F 41.27 mV VR27 -10V TP 13
7 (TOil) G 8.14 mV VR31 -2.0V TP 15

8 (spare) H 8.14 mV VR35 -2.0V TP 17

d) Analogue Output for Data Logging - Full Scale Adjustment.

Set jumpers J1 to J8 to position A. For each channel in turn connect the millivolt source to the
thermocouple socket shown in column 2 of the following table and inject the voltage shown in
column 3. Adjust the variable resistor listed in column 4 to obtain +10V at the test point listed in
column 5 (relative to test point TP1).
T/C
Channel mV inject Adjust Reading
Socket
1 (T2) A 6.54 mV VR3 TP 4
2 (T1) B 2.022 mV VR7 TP 6
3 (Tg) C 2.022 mV VR11 TP 8
4 (T3) D 41.27 mV VR15 TP 10
5 (T4) E 41.27 mV VR24 TP 12

6 (T5) F 41.27 mV VR28 TP 14
7 (TOil) G 8.14 mV VR32 TP 16
8 (spare) H 8.14 mV VR36 TP 18
e) Cold Junction Compensation.

Set jumper link J9 to position A. Measure the voltage across edge connector pins 21c (+ve) and
22a (-ve) and adjust variable resistor VR38 to obtain the same reading between test points TP2
and TP1.
f) Front Panel Meter - Full Scale Adjustment.
With jumper links J1 to J9 in position A, then for each channel in turn connect the millivolt
source to the thermocouple socket shown in column 2 of the following table and inject the
voltage shown in column 3. Adjust the variable resistor shown in column 4 to obtain the front
panel reading shown in column 5. It will be necessary to depress the appropriate temperature
selection buttons on the front panel whilst making these adjustments. Adjustment of channel 8 is
not required as it is not connected to a front panel instrument.

T/C
Channel mV inject Adjust Reading
Socket
1 (T2) A 6.54 mV VR4 160°C

2 (T1) B 2.022 mV VR8 50°C
3 (Tg) C 2.022 mV VR12 50°C
4 (T3) D 41.27 mV VR16 1000°C
5 (T4) E 41.27 mV VR25 1000°C
6 (T5) F 41.27 mV VR29 1000°C
7 (TOil) G 8.14 mV VR33 200°C
8 (spare) H 8.14 mV - -
6.3.3 Turbine Inlet Temperature - Over Temperature Trip.

With jumper links J and J9 in position A, inject 37.6 mV (equivalent to 907°C) into thermocouple
socket D and adjust VR21 so that LED 4 is extinguished. Reduce the injected voltage to 37.4 mV
(≡902ºC) and check that LED 4 illuminates and that relay D energises. Increase the injected
voltage to 37.6 mV again and check that LED 4 goes out and that relay D de-energises.
6.4 Maintenance.
a) Lubricating Oil.
The oil in this system undergoes little deterioration and is only changed if the system has to be
dismantled for any reason. Always use the oil specified - oils of higher viscosity, such as normal
motor oils, make starting difficult and reduce the turbine’s overall performance. The oil level
should only be half way up the oil tank as gas blow-by may cause overflowing if the tank is too
full. After initial filling, run the oil pump for a minute to fill the oil filter etc., and then ensure that
the correct oil level in the tank is obtained by adding oil if required.
b) Toothed Turbine-Generator Driving Belt.
The tension of this belt is automatically controlled by a hydraulic ram fed from the lubricating oil
circuit.
6.5 Additional Calibration Procedure for P9008 Option.

If the signal conditioning option P9008 has been fitted then additional calibration procedures
apply. All of the pressure transducers contain integral amplifiers which are pre-calibrated and
sealed by the manufacturer and thus require no further attention. The air and fuel flow
measurement and the alternator voltage and current measurement utilise Cussons analogue
computing board CBA 220 and although these channels have been factory set prior to dispatch,
the following procedures can be applied if the output signal voltages do not confirm the front
panel analogue instrumentation.

6.5.1 Preparatory Work.

Open the hinge-down lid of the control cubicle and pull out the analogue computing printed
circuit board CBA 220 from its edge connector and reconnect it via a DIN 41612 64-way (rows a
and c) extender card. The four measurement channels involved are each spanned by comparison
with the front panel instruments whilst the gas turbine is running. Therefore, start the gas turbine
following the normal procedure and establish steady state conditions at a near maximum speed
and power output. Adjust the gas pressure regulating valve to obtain a pressure at the gas
rotameter of 1.5 bar gauge.
6.5.2 Fuel Flow.

The fuel flow is measured by a 0 - 175 mbar differential pressure transducer connected across an
orifice placed in series with the fuel front panel rotameter. The 0 - 5V dc output from the integral
transducer amplifier is square rooted and amplified on printed circuit board CBA 220 to give a
signal scaled 0 – 0.0016m3/s which will correspond with the rotameter measurement range of
0 - 3.2 g/s when the gas conditions are 15°C and 1.5 bar. Connect the digital voltmeter between
test points 9 and 1 and adjust VR10 to obtain a voltage reading of 3.125 times the rotameter
reading, (i.e. if the gas flow is 2.0 g/s then the voltage at TP9 should be 3.125 x 2.0 = 6.25V).
6.5.3 Air Flow.

Air flow is sensed by a 0 - 20mbar differential pressure transducer connected directly across the
pitot-reversed pitot tube. The 0 - 10V dc output from the transducer amplifier is square rooted
and amplified by circuits on the CBA 220 printed circuit board to provide a signal which is
proportional to air flow rate. The full scale is taken to be equivalent to a differential pressure of
200mm of H2O which will correspond to an air mass flow of k√200 in gram/second where k is
the meter constant shown on the engraved meter plate. Connect the digital voltmeter between test
K × 200
points 8 and 1. Apply 200mm H2O, set o/p to × 10 = V o/p at TP8 adjusted by VR9.
175
6.5.4 Alternator Voltage.

The alternator output voltage is detected and measured by a hall effect sensor, which is connected
to a root mean square to dc circuit and amplifier on printed circuit board CBA 220. Connect a
digital voltmeter between test points TP6 and TP1, check that jumper J1 is in position A. With
the power turbine running in a steady state, high power condition, adjust VR4 to give a signal at
TP6 of one tenth of the front panel voltmeter instrument reading, (i.e. 6V at TP6 corresponds to
60V on the front panel voltmeter).
6.5.5 Alternator Current.

The alternator current is also sensed by a hall effect device coupled into the alternator output
circuit by a torroidal transformer. A similar root mean square to dc circuit is used which is scaled
to provide 0 - 10V corresponding to an alternator current output of 0 - 50A. The signal
conditioner output is adjusted by VR7 so that the voltage at test point TP7 on CBA 220 gives a
voltage reading equal to one fifth of the current. (i.e. If the alternator output current is 25A, then
the voltage at TP7 should be 5V).

7 OPERATING INSTRUCTIONS
7.1 General.
The Cussons Gas Turbine Unit incorporates a gas generator driving a free power turbine which
drives an alternator. The gas generator consists of a centrifugal compressor, a single gas fuelled
tubular combustion chamber and a radial turbine. The free power turbine is also of radial design,
with a belt drive to the alternator. The unit is designed to permit analysis of the performance
characteristics of the gas generator, power turbine and combustion chamber using the
instrumentation displayed on the front panel. Operation over a wide range of speed and load is
possible which, together with the facility for varying the speed ratio between the gas generator
and the power turbine, means that a test programme on the Two Shaft Gas Turbine system can be
carried out. By carefully controlling the speed ratio of the gas generator and free power turbine to
a constant value, a coupled power turbine can be simulated, whereas if the free power turbine
speed is held constant, then the gas generator simulates a single spool turbo jet.
7.2 Starting.
1. Connect the cooling water supply and drain.
2. Connect the gas bottle.
3. Connect the electrical supply.
4. Set the air inlet control to the start position.
5. Close the gas valve and open the valve on the gas bottle.
6. Set the dynamometer excitation to maximum.
7. Start the oil pump.
8. Press the reset button.
9. Start the blower.
10. Set the gas pressure to 200 Kpa (2.0 bar) with the reducing valve.
11. Press the ignition button and hold it in whilst opening the gas valve to give a gas flow of
0.5 g/s.
12. If ignition, as shown by an increase in T3, does not occur within 5 seconds of gas flow
commencing, close the gas valve to allow unburnt gas to clear the system before
continuing from item 11.
13. Release the ignition button.
14. Open the gas valve slowly to give a gas generator speed of 1000 rev/s taking care to keep
combustion chamber temperature below 900°C (this operation may take some minutes
depending on the oil temperature).
15. Turn the air inlet control to the run position.
16. Switch off the blower.
7.3 Operating Limitations.

1. During the test programme the following limits must not be exceeded :

Gas generator speed 2000 rev/s

Power turbine speed 600 rev/s
Gas generator turbine inlet temperature 900°C
2. Set the gas pressure to 150 KPa (1.5 bar) before making fuel flow readings.
3. The gas turbine unit has certain safety features built into it. If the combustion chamber
temperature T3 is allowed to exceed 900°C due to overfuelling, or if the oil pressure falls
below 150 KPa (1.5 bar), then the gas supply will be shut off by means of a solenoid
valve. To re-start the turbine after operation of the solenoid valve, follow starting
instructions 4 - 17.
7.4 Stopping.
1. Close the valve on the gas bottle.
2. Close the gas valve.
3. Once the turbines have stopped reset the air inlet control to the start position.
4. Re-start the blower.
5. When T4 has dropped below 80°C and the oil temperatuer drops below 40°C :
i) Switch off the blower.
ii) Switch off the oil pump.
iii) Turn off the gas supply.
iv) Turn off the water supply.
v) Turn off and disconnect the electrical supply.
7.5 Notes on Operating Instructions.

7.5.1 Starting.
When ignition initially occurs, a slight ‘pop’ is heard, and a sharp rise of combustion chamber
temperature (T3) takes place. If the gas valve is then opened too quickly, T3 will rise above 950°C
and the over temperature protection will operate. Should this occur, close the gas valve, press the
‘reset’ button and restart the turbine as in 7.2 Starting. Whilst accelerating T3 should be kept
below 850°C by ‘slowly’ opening the gas valve as the turbine speed increases. When the gas
generator speed reaches 1000 rps, leave the gas valve in this position and turn the air inlet control
switch to the run position and switch off the blower.
7.5.2 Operation.
When varying the load on the power turbine, sudden large movements of the dynamometer
exciter control should be avoided, so that high transient belt loads (which may cause the belt to
jump the pulleys and cause damage) can be avoided. It is convenient when taking a set of
readings to first set the fuel flow at the desired level by adjustment of the fuel control valve, and
then (if required) trimming the reducing valve to give a fuel supply pressure of 150 KPa (1.5 bar).

7.5.3 Stopping.
When the turbine has been stopped and the system is being cooled by operating the blower, it is
essential to leave the blower running until the temperature of T4 has dropped to less than 80°C
and the oil temperature to less than 40°C.

FRONT PANEL LAYOUT OF GAS TURBINE UNIT

FIG. 1

A - INLET AIR SILENCER

B - COMPRESSOR
C - COMBUSTION CHAMBER
D - GAS GENERATOR TURBINE
E - POWER TURBINE
F - EXHAUST SILENCER
G - STARTING AIR COMPRESSOR
H - DYNAMOMETER
I - OIL RESERVOIR
J - OIL PUMP
K - OIL COOLER
L - MAINS ELECTRICAL INPUT
M - OVER-TEMPERATURE CUT OUT
FIG. 2 REAR VIEW OF GAS TURBINE UNIT


Flow Patterns in a Single Circular Combustion Chamber.
FIG. 4 INNER COMBUSTION CHAMBER DETAILS

FIG. 5 AC 7 ALTERNATOR CALIBRATION

(P9005/245 ONWARDS)
LUBRICATION SYSTEM
FIG. 6

(UPTO P9005/244)
FIG. 6 LUBRICATION SYSTEM

m& C CORRECTED AIR FLOW @ 288 K and 1.01325 bar (kg√K/s bar)

Fig 8 - Gas Generator Turbine Characteristic
1.5
Tt3 = Total Turbine Inlet Temp (K)
Pt3 = Total Turbine Inlet Pressure (bar Abs)

1.45
Pt4 = Total Turbine Outlet Pressure (bar Abs)
& = Mass Flow Rate (kg/sec)

m
1.4
Pt3
Turbine Expansion Ratio
= Turbine Expansion Ratio

Pt 4
1.35
& Tt 3
m
= Semi Dimensional Mass Flow Parameter (kg√K/s)
Pt 3
1.3
1.25
1.2
1.15
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
Semi-dimensional Mass Flow Paramater

Fig 9 - Free Power Turbine Characteristic
1.16
Tt4 = Total Turbine Inlet Temp (K)

1.15
Pt4 = Total Turbine Inlet Pressure (bar Abs)
1.14
Pt5 = Total Turbine Outlet Pressure (bar Abs)
1.13 & = Mass Flow Rate (kg/sec)

m
Turbine Expansion Ratio
1.12 Pt 4
= Turbine Expansion Ratio
P5
1.11
& Tt 4
m
= Semi Dimensional Mass Flow Parameter (kg√K/s)
1.1 Pt 4
1.09
1.08
1.07
1.06
1.05
2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6 3.8 4
Semi-dimensional Mass Flow Parameter

FIGURE 10 PRINTED CIRCUIT BOARD CBA 216 (SPEED)

Two Shaft Gas Turbine Test Results
FUEL FLOW AIR FLOW OIL PRESSURES TEMPERATURES SPEEDS POWER OUTPUT
Mf Tg Pg g/sec P-RP Toil P3 P4 P2-P3 T1 T2 T3 T4 T5 G.G P.T Voltage Current Correct Power
gram/sec ºC KPa mm H2O ºC bar bar mm Hg ºC ºC ºC ºC ºC rev/sec rev/sec V A Factor WATTS
2.34 18.26 154 148.72 64.40 0.69 0.15 18.99 93.98 726.07 624.76 501.95 1514.16 612.11 64.50 29.80 1922.0
2.12 18.47 148 134.45 65.63 0.58 0.13 18.77 83.59 713.38 622.31 505.86 1398.44 608.59 54.69 25.62 1401.2
1.87 19.06 150 120.53 62.89 0.48 0.10 19.17 74.45 699.71 615.97 500.73 1281.25 602.73 44.78 21.28 952.7
1.69 19.56 152 107.92 60.50 0.40 0.09 19.31 67.07 700.20 618.65 501.95 1179.69 611.33 35.84 17.26 618.6
1.54 19.92 154 96.51 58.64 0.33 0.08 19.25 60.94 712.16 630.13 511.23 1085.45 608.01 27.42 13.35 366.1
1.43 21.09 150 83.91 56.45 0.27 0.06 19.54 55.27 747.31 656.25 529.05 977.05 608.59 14.92 7.30 108.9
T3 OVER TEMPERATURE SETTING 900ºC PITOT - REVERSE PITOT CONSTANT DATE TEST COMPLETED
BELT TENSIONING RAM PRESSURE KPa AIR FLOW CALIBRATION EQUATION:- TEST ENGINEERS SIGNATURE
M air = 11.51{h} 0.5
Remarks

FIG. 11 P9005 GAS TURBINE TEST SHEET
SERIAL NUMBER
FUEL FLOW AIR FLOW OIL PRESSURES TEMPERATURES SPEEDS POWER OUTPUT
Mf Tg Pg g/sec P-RP Toil P3 P4 P2-P3 T1 T2 T3 T4 T5 G.G P.T Voltage Current Correct Power
gram/sec ºC KPa mm H2O ºC KPa KPa mm Hg ºC ºC ºC ºC ºC rev/sec rev/sec V A Factor WATTS
T3 OVER TEMPERATURE SETTING ºC PITOT - REVERSE PITOT CONSTANT DATE TEST COMPLETED
WATER THERMOSTAT SETTING ºC AIR FLOW CALIBRATION EQUATION:- TEST ENGINEERS SIGNATURE
0.5
BELT TENSIONING RAM PRESSURE KPa M air = {h} TEST SUPERVISORS SIGNATURE
Remarks

FIG. 12 CORRECTION FACTOR CURVES FOR FUEL FLOWMETER

REF. R768146-55 WHEN USED WITH PROPANE
AT 150 KPa (1.5 bar) GAUGE AND VARIOUS TEMPERATURES

FIGURE 13

FIGURE 14 PRINTED CIRCUIT BOARD 219 (TEMPERATURES)

FIGURE 15 PRINTED CIRCUIT BOARD 220 (ANALOGUE COMPUTING) P9008 OPTIONAL EXTRA

FIGURE 16 OVERALL SCHEMATIC DIAGRAM


8 APPENDIX I – A FIRST COURSE IN GAS TURBINE

TECHNOLOGY




































































9 APPENDIX II – POWER TURBINE























































10 APPENDIX III – GAS GENERATOR




















































11 APPENDIX IV – LOADING UNIT












P9005manu Gas Turbine

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P9005_8 – Cussons Technology – Two Shaft Gas Turbine Page 1 of 232

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

2 HEALTH AND SAFETY WARNINGS AND PRECAUTIONS ........................................... 7

4 GENERAL SPECIFICATION .....................................................................................11

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

5.8.2 Pressure. ....................................................................................................... 15

6 INSTALLATION, COMMISSIONING, CALIBRATION AND MAINTENANCE.............19

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

7.3 Operating Limitations.......................................................................................25

8 APPENDIX I – A FIRST COURSE IN GAS TURBINE TECHNOLOGY ........................47

9 APPENDIX II – POWER TURBINE ........................................................................115

10 APPENDIX III – GAS GENERATOR ....................................................................170

11 APPENDIX IV – LOADING UNIT ........................................................................222

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

ILLUSTRATIONS AND GRAPHS

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

1 RECEIPT AND UNPACKING

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

2 HEALTH AND SAFETY WARNINGS AND PRECAUTIONS

2.1 Manufacturers Liability.

Cussons Technology Ltd

Telephone +44 (0)161 833 0036

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

d) The equipment must be subject to periodic inspection and testing to ensure

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

4.2 Gas Generator.

4.3 Power Turbine.

4.4 Loading Alternator with Silicon Diode Rectifying Circuit.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

4.5.3 Temperature Measurement.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

5.2 Gas Generator.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

5.3 Power Turbine.

5.4 Loading System for Power Turbine.

5.5 Starting System.

5.6 Ignition System.

5.7 Lubrication System.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

5.8.4 Fuel Flow Rate.

5.9 Operational Interlocks.

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

5.10 Signal Conditioning for Data Logging (P9008 optional extra).

Pin Channel Description Mnemonic Range

1 0 Oil temperature To 0 - 200° C

2 Common Analogue ground - -

6 1 Oil pressure P 0 - 10 bar

cussons 102, Great Clowes Street. Manchester M7 1RH. U.K.

Socket 2 25 pin D Connector - Analytical Socket.

1 Common Analog ground - -

6 8 Power turbine inlet pressure P4 0 - 400 mbar

7 9 Gas pressure Pg 0 - 4 bar

8 15 Fuel flow ∆Ρg 0 - 3.2 g/s

9 14 Gas generator speed Ngg 0 - 2000 rev/s

10 13 Turbine speed NPT 0 - 800 rev/s

11 12 Alternator current I 0 - 50 amps

12 11 Alternator volts V 0 - 100 volts

13 10 Air flow ∆Ρa 0 - 175 g/s

19 1 Compressor exit temperature T2 0 - 160°C

20 2 Gas generator inlet temperature T3 0 - 1000°C

21 7 Gas generator inlet pressure P3 0 - 2 bar