MBEYA UNIVERSITY OF SCIENCE AND TECHNOLOGY

MUST RUKWA CAMPUS COLLEGE

MECHANICAL AND INDUSTRIAL ENGINEERING DEPPARTMENT

INDUSTRIAL PRACTICAL TRAINING REPORT

TANESCO KINYEREZI 1 GAS POWER PLANT

UE/DME/23/0126

23201223200005
DECLARATION
I, John Dickens Msongo, declare that, this is my report showing all activities I have
participated and done in the Generation-Maintenance Section at Tanzania Electric
Supply Company Limited (TANESCO). KINYEREZI 1 (ONE) GAS POWER
PLANT, (TANESCO) a Tanzanian parastatal organization established in 1964. It is
wholly owned by the government of Tanzania. The Ministry of Energy and Minerals
regulates the operations of TANESCO. Its business includes electricity generation,
electricity transmission, electricity distribution and sale of electricity to the Tanzanian
mainland and bulk power supply to the island of Zanzibar. During my training I was
under the Professional training supervisor .Eng. Geofrey Mdegela
Name of trainee: -John Dickens Msongo
Mobile phone: +255 625752256
Email: [email protected],
Professional Training Supervisor (PTS): - Eng. Mdegela
Phone number: +255 765 878 841
Table1: Details of the trainee agreement

Trainee Name: John Dickens Msongo

Discipline: Mechanical Engineering
Phone number: +255625752256
Email: [email protected]
Training organization Name: Tanzania Electricity Supply Company,
Kinyerezi 1 Gas Power Plant
Address: P.O.BOX 9024
Region: Dar es salaam
Telephone: +255 222 455 1130
Email: @tanesco.co.tz
Professional Training Name: Eng. Geofrey Mdegela
supervisor Phone number: +255 765 878 841
Email: @tanesco.co.tz
TANESCO Professional Name: Eng. Geofrey Mdegela
Training Coordinator Position: Maintenance Engineer
Supervisor Address: P.O.BOX, Dar es salaam
Phone Number: +255 765 878 841
Email: @tanesco.co.tz
Training Period Duration: 8th July 2024 to13th September 2024
LIST OF ABBREVIATIONS

GLO Generator Lube Oil

CDP Compressor Discharge Pressure
GPRS Gas Pressure Reduction System
GTG Gas Turbine Generator
HLO Hydraulic Lube Oil
TLO Turbine Lube Oil
HPT High Pressure Turbine
LPT Low Pressure Turbine
TANESCO Tanzania Electricity Supply Company
VBV Variable Bypass Valve
VSV Variable Stator Vanes
LPC Low Pressure Compressor
HPC High Pressure Compressor
VIGV Variable Inlet Guide Vane
TABLE OF CONTENT
DECLARATION…………………………………………………………………….I
DETAILS OF AGREEMENT……………………………………………………….II
LIST OF ABBREVIATIONS………………………………………………………..III
CHAPTER 1………………………………………………………………………….1
1.0 INTRODUCTION………………………………………………………………..1
1.1 BACKGROUND INFORMATION……………………………………………...1
1.1 ORGANIZATION STRUCTURE………………………………………………..2
CHAPTER 2…………………………………………………………………………..3
2.0 TECHNICAL REPORT…………………………………………………………..3
2.0 TITLE: HOW GAS TURINE GENERATES POWER…………………………..3
2.1 INTRODUCTION………………………………………………………………..3
2.1.1 MAIN PARTS OF GTG………………………………………………………..4
2.1.2 OPERATION OF GTG...………………………………………………………15
CHAPTER 3………………………………………………………………………….17
3.0 CHALLENGES…………………………………………………………………..17
3.1 RECOMMENDATIONS………………………………………………………...17
3.2 CONCLUSION…………………………………………………………………..17
REFERENCES…………………………………………………………………..…..18
 CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND INFORMATION.
Tanzania Electric Supply Company Limited (TANESCO) is a parastatal organization
under the ministry of Energy established in 1964. The Company generates,
purchases, transmits, distributes and sells electricity to Tanzania Mainland and sells
bulk power to the Zanzibar Electricity Corporation (ZECO), which in turn sells it to
the public in islands of Unguja and Pemba. TANESCO owns most of the electricity
generating, transmitting and distributing facilities in Tanzania Mainland with
estimated population of 60 million.

Kinyerezi 1 Power Plant started its generation on13 th October, 2015 with 4 Operating
units i.e. GTG1, GTG2, GTG3 & GTG4 for phase 1. GTG1&GTG2 are installed with
chiller system having installed capacity 40MW each while GT3&GT4 are Installed
without chiller and has installed capacity 35MW each. And another 4 units i.e GTG5,
GTG6,GTG7 & GTG8 for Kinyerezi 1 Extension or phase 2 which have capacity of
185 MW. The type of turbine used is LM6000pf supplied by GE USA which uses
either natural gas or JET A1 fuel to generate electricity. The first full Commissioning
of Kinyerezi 1 Gas plant was on 31 march,2016 through which the Plant generated
Power to its full installed Capacity of 150MW. The plant dispatches its power to the
national grid through 220kv Transmission line.Currently Kinyerezi 1 at full capacity
produces 335 MW in total.
.

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1.2 ORGANIZATION STRUCTURE
The following is the organization structure at KINYEREZI 1 GAS POWER PLANT

PLANT MANAGER

STORE AND PRINCIPAL HUMAN PRINCIPAL

PROCUREMENT HEALTH AND
LOGISTICS ACCONTANT MAINTENANCE RESOURCE OPERATION
OFFICER SAFETY OFFICER
OFFICER ENGINEER OFFICER ENGINEER

ASS. STORE AND ASSISTANT

ASSISTANT MECHANICAL PLANNING ELECTRICAL GENERATION
LOGISTICS PROCUREMENT
ACCOUNTANT ENGINEER ENGINEER ENGINEER ENGINEER
OFFICER OFFICER

A/C AND
MECHANICAL ELECTRICAL
DRIVERS REFRIGERATION
TECHNICIANS TECHNICIANS
TECHNICIANS

ARTISANS ARTISANS ARTISANS

Figure 2: Organization Structure of Kinyerezi 01 Gas power plant.

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 CHAPTER TWO
TECHNICAL REPORT
2.0 TITLE: GENERATION OF POWER THROUGH GAS TURBINE
2.1 Introduction
The General Electric LM6000 gas turbine is a stationary gas turbine that is derived
from the family of CF6 jet engines. The aircraft version of the engine is called the
CF6-80C2 turbofan engine and is used to drive several types of “wide body”
commercial aircraft, including the Boeing 747-400.
The LM (Land and Marine) series of gas turbines has the following gas turbines:
LM500,LM1500,LM1600,LM2500,LM2500+,LM5000,LM6000.

Image of the LM6000

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2.1.1 MAIN PARTS OF GTG
The major components of GTG include the following;
 Inlet Volute
 Variable inlet guide vane (VIGV) assembly
 Low-pressure compressor (LPC) assembly
 Low-pressure compressor bypass-air collector
 Variable bypass valve system
 Low-pressure compressor front frame assembly
 High-pressure compressor (HPC) assembly
 Compressor rear frame assembly
 Combustor assembly
 High-pressure turbine assembly
 Low-pressure turbine assembly
 Turbine rear frame assembly
 Accessory gearbox

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AIR INLET VOLUTE
The Air Inlet Volute provides for a smooth transition of airflow from the air filter
enclosure into the first stage of the low pressure compressor. The volute changes the
airflow direction from a vertical to a horizontal flow. The air inlet casing assembly
comprises an external casing, approximately rectangular in shape, and forms a
circular internal casing to which the low pressure compressor mounts. The generator
drive shafts then runs through the center of the volute to the generator

Image of inlet volute

LPC Mounting face

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INLET GUIDE VANE ASSEMBLY
Variable Inlet Guide Vane Assembly (VIGV) is located at the front of the LPC. It
allows flow modulation at partial power, resulting in increased engine efficiency. The
VIGV system consists of 43 stationary, leading-edge vanes and variable trailing flaps.
The variable flaps can be rotated from −10 degrees open to +60 degrees closed by
means of an actuation ring.which is driven by twin hydraulic actuators.

Image of inlet guide vanes

LOW-PRESSURE COMPRESSOR (LPC) ASSEMBLY

The LM6000 LPC is a 5-stage, axial-flow compressor with a 5-stage fixed stator. The
LPC stator case contains the stator vanes for the LPC rotor. The case is horizontally
split to facilitate repair.

Image of LPC assembly

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LOW PRESSURE COMPRESSOR BYPASS AIR COLLECTOR
The LPC bypass-air collector is a duct attached to the front frame. It collects LPC
discharge air, vented through the LPC bypass doors, and directs it overboard through
packager-provided ducting.
VARIABLE BYPASS VALVE SYSTEM
The variable bypass valve (VBV) system is located in the front frame assembly. This
system is used to vent LPC discharge air overboard through the LPC bypass-air
collector in order to maintain LPC stall margin during starting, partial power
operation, and large power transients. The VBV system consists of 12 variable-
position bypass valves, 6 VBV actuators (two with LVDTs) Linear Variable
Differential Transformer, 6 actuator bell cranks, 12 VBV doorbell cranks, and an
actuation ring.

VBV image

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 VBV actuators
LOW PRESSURE COMPRESSOR FRONT FRAME ASSEMBLY
The front frame is a major structure that provides support for the LPC rotor and the
forward end of the HPC rotor through the No. 1B, No. 2R, and No. 3R bearings. The
frame also forms an airflow path between the LPC and the HPC inlet. Front engine
mount provisions are located on the front frame 3 o’clock and 9 o’clock positions.
One pad is included on the frame outer case for mounting HPC inlet temperature
sensors T2.5 and HPC pressure sensor P2.5. The sensors provide control information
to the fuel management system.
The front frame contains the engine A-sump, which includes a thrust bearing and
roller bearing that support the LPC rotor, and a roller bearing that supports the
forward end of the HPC rotor. Lubrication oil supply and scavenge lines for the A
sump are routed inside the frame struts. The inlet gearbox is located in the A sump
with the radial drive shaft extending outward through the strut.

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 LPC Front frame assembly

HIGH PRESSURE COMPRESSOR (HPC) ASSEMBLY

The LM6000 HPC is a 14-stage, axial-flow compressor. It incorporates VIGVs and
variable stators in stages 0–5 to provide stall-free operation and high efficiency
throughout the starting and operating range. Provisions for customer-use bleed air are
available at stage 8 and at the compressor discharge.Compressor discharge air is
extracted for cooling and pressurization of the engine components.

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 Image of HPC assembly

VARIABLE STATOR VANE ASSEMBLY

The VSV assembly, an integral part of the HPC stator, consists of two VSV actuators
and levers, actuation rings, and linkages for each VSV stage. Stator vane position is
vital to stable, efficient operation of the engine. While the HPC is designed for peak
aerodynamic efficiency at full power and full speed, it must also operate at lower
speeds. At these lower speeds, the later stages of the compressor cannot consume all
the air delivered by the earlier stages. The variable stators accommodate this situation
by limiting the compression ratio of the first six stages of the compressor at low
speeds and changing the compression at higher speeds. This is accomplished with two
hydraulic actuators.

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 Image of VSV assembly

Image of actuator

Image of VSV actuation rings

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COMBUSTOR ASSEMBLY
The LM6000 gas turbine uses a singular annular combustor and is furnished with 30
externally mounted fuel nozzles for liquid distillate fuel, natural gas fuel, or dual fuel,
depending upon the fuel system specified by the customer. Fuel systems may also be
equipped for water or steam injection for NOx suppression. This combustion system
is a high-performance design that has consistently demonstrated low exit temperature
pattern factors, low-pressure loss, low smoke, and high combustion efficiency at all
operating conditions.
SINGULAR ANNULAR COMBUSTOR
Key features of the singular annular combustor are the rolled-ring inner and outer
liners; the low-smoke emission, swirl-cup dome design and the short burning length.
The short burning length reduces liner cooling air consumption, which improves the
exit temperature pattern factor and profile. The swirl-cup dome design serves to
leanout the fuel-air mixture in the primary zone of the combustor. This eliminates the
formation of the high-carbon visible smoke that can result from over-rich burning in
this zone.

HIGH-PRESSURE TURBINE ASSEMBLY

The LM6000 HPT is an air-cooled, two-stage design with demonstrated high
efficiency. The HPT system consists of the HPT rotor and the stage 1 and stage 2
HPT nozzles. The HPT assembly drives the HPC rotor by extracting energy from the
hot-gas path stream.
HPT ROTOR
The HPT rotor assembly consists of the stage 1 disk and integral shaft, a conical
impeller spacer with cover, a thermal shield and a stage-2 disk. Forward and aft
rotating air seals are assembled to the HPT rotor and provide air-cooled cavities
around the rotor system.

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 HPT Assembly

LOW-PRESSURE TURBINE ASSEMBLY

The LPT drives the LPC and load device using the core gas turbine discharge gas
flow for energy. The principal components of the LPT module are a five-stage stator.
LPT ROTOR
The LPT rotor assembly drives the LPC through the LP mid-shaft and drives a load
through either the mid-shaft or from an aft drive adapter on the rear of the LPT rotor.
The LPT rotor assembly consists of five stages of bladed disks and a shaft sub-
assembly.

LPT Assembly

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ACCESSORY GEARBOX
Engine starting, lubrication, and speed monitoring of the HP rotor shaft are
accomplished by accessories mounted on the accessory gearbox (AGB).
The AGB is mounted beneath the gas generator at the compressor’s front frame.
Fitted to the aft side of the gearbox is the hydraulic starting motor clutch, which
drives the transfer gearbox, radial drive shaft, and inlet gearbox in A-sump to rotate
the HPC rotor.
The following accessories are mounted on the AGB:
 Hydraulic starting motor
 Clutch assembly
 Variable-geometry control unit
 Engine lube oil pump
 Fuel-metering valve hydraulic oil pump
 Transfer gearbox
 Radial drive shaft

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2.1.2 OPERATION OF GTG
The major components of the engine are a compressor section, combustion section,
and a turbine. The turbine is mechanically coupled and drives the compressor by a
drive shaft. The compressor, combustor, and turbine are called the core of the engine,
since all gas turbines have these components. The core is also referred to as the gas
generator (GG) since the output of the core is hot exhaust gas. The gas is passed
through an exhaust duct to atmosphere. On some types of applications, the exhaust
gas is used to drive an additional turbine called the power turbine which is connected
to a piece of driven equipment i.e generator for producing electricity.
CYCLE OF OPERATION OF GTG
COMPRESSION(A) – COMBUSTION(B) – EXPANSION(C) – EXHAUST(D)
Four processes occur in gas turbine engines, as illustrated above. These processes,
first described by George Brayton and called the Brayton cycle, occur in all internal
combustion engines. The Brayton steps are as follows:
Compression occurs between the intake and the outlet of the compressor (Line A-B).
During this process, pressure and temperature of the air increases
Combustion occurs in the combustion chamber where fuel and air are mixed to
explosive proportions and ignited. The addition of heat causes a sharp increase in
volume (Line BC)
Expansion occurs as hot gas accelerates from the combustion chamber. The gases at
constant pressure and increased volume enter the turbine and expand through it. The
sharp decrease in pressure and temperature (Line C-D).
Exhaust occurs at the engine exhaust stack with a large drop in volume and at a
constant pressure (Line D-A)

This process is similar to reciprocating engines used in cars with the four-stroke cycle.

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 Image of Gas Turbine operation VS Reciprocating Engine Operation

POWER TRANSMITION TO GENERATOR

A shaft is used transmit power from engine to the generator an 11.5kV generator to
produce electricity. The LM6000 as used at Kinyerezi 1 Gas Power Plant is a dual
shaft(two shaft) connecting from the LPT all the way to the Generator at the front thus
transmitting the Mechanical power generated into electrical power.
The concentric shaft illustration, below, shows a more complicated aero-derivative
industrial turbine arrangement. This, too, is still essentially a two shaft configuration
but the gas generator core (an original jet-engine) was designed with two spools, a
Low Pressure Shaft and a High Pressure Shaft. This engine configuration allows the
load to be driven from either the exhaust end or the compressor air intake end. This is
the configuration used by the LM6000

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 CHAPTER THREE
3.0 CHALLENGES IN OPERATING GTG
 Require heavy machinery for operation and maintenance
 Heavy Weight of some parts such as motors makes it difficult to replace
 Manufactured parts require import thus long time to access them

3.1 RECOMMENDATIONS
 Government should be advised to order more manufactured parts for easy
accessibility
 More machinery should be brought to the plant to aid in lifting and moving heavy
parts

3.2 CONCLUSION
The LM6000 is a highly efficient, reliable, and versatile aeroderivative gas turbine
engine that offers numerous benefits for various industrial and marine applications. Its
exceptional thermal efficiency, rapid start-up time, versatility, reliability, and low
emissions make it a preferred choice for power generation. The LM6000 has a proven
track record of success and continues to be a valuable asset in the energy industries.

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REFERENCES
1) TANESCO Kinyerezi 1 power station, https://tanesco.co.tz
2) GEVernovaLM6000productpage::https://m.youtube.com/watch?v=7qIB9EjKsFA
3) GEVernovaDatasheet:https://www.geaerospace.com/sites/default/files/datasheet-
lm6000.pd
4) https://photos.app.goo.gl/b7D5GN9ZVa41qyqm6

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