Solar Turbines Incorporated specializes in industrial gas turbine design, manufacturing, and installation, with over 12,500 installations globally. The Mars 90 and 100 compressor sets and mechanical drives are engineered to high standards and certified to ISO 9001:2000 for quality management.

This section details the Mars 90 and 100 gas turbine mechanical drives, including package configurations and ancillary equipment.

Provides a general description of the Mars gas turbine, highlighting its design and operational capabilities.

Describes the compressor set packages, including the Solar gas compressors and their integration with the Mars turbines.

Outlines the mechanical drive packages, focusing on their components and operational features.

Provides a general description of the gearbox used in the turbomachinery package.

Describes the start systems available, including the direct-drive AC start system and the optional pneumatic start system.

Details the fuel system's general description and schematic.

Explains the lubrication system's components and functionality.

Describes the control system architecture, components, and monitoring functions.

Provides an overview of the process control and monitoring systems.

Details the enclosure's standard and optional features.

Describes the air inlet system configurations and their specifications.

Outlines the exhaust system and the turbine exhaust heat recovery system.

Includes descriptions of the battery charger system and turbine cleaning system.

Provides a general description of the marinization process for offshore applications.

Details the quality assurance processes and testing procedures.

Outlines the preservation, site requirements, installation, and documentation processes.

Describes the certification standards, including NEC, CEC, CE Mark, and IEC safety assessments.

Lists the support services available, including construction, customer services, and leasing options.

The document provides a detailed specification of the Mars 90 and 100 Compressor Set and Mechanical Drive by Solar Turbines Incorporated. It outlines the integration of the mechanical drive with Solar gas compressors and third-party equipment, emphasizing the control and monitoring systems integrated into Solar's Turbotronic control system.

• General Description: The Mars gas turbine mechanical drive package is fully integrated and operational, designed for industrial service with compact and lightweight features to minimize installation costs and time.
• Package Description: Installed on a steel skid, the package includes major components such as the gas turbine, start system, fuel system, lubricating oil system, Turbotronic 4 Control System, and ancillary systems.
• Electrical System: The onskid electrical system meets various certification requirements, including NEC, CEC, and CE Mark. Off-skid components must be installed in nonhazardous areas.
• Service Connections: Self-contained systems for starting, fuel, lube oil, and control with conveniently located service connections.

• Dimensions and Weights: Detailed measurements and weights for both enclosed and unenclosed packages.
• Construction Materials: Primarily 316L stainless steel for piping and tubing, with optional carbon steel components.
• Electrical System Certifications: Compliance with NEC, CENELEC, and ATEX standards.

• General Description: A two-shaft, self-contained prime mover designed for high efficiency and low maintenance, compliant with API requirements.
• Principles of Operation: Describes the combustion process and energy conversion in the turbine.
• SoLoNOx Combustion System: An optional system to reduce emissions by limiting NOx, CO, and UHC formation.

• Compressor Set Packages: Fully integrated packages with Mars gas turbines driving Solar centrifugal gas compressors, available in various configurations for different pressure ratios.
• Solar Gas Compressors: Designed for simplicity and flexibility, with features conforming to API 617 standards, suitable for both gas production and pipeline applications.

• Package Specifications: Includes dimensions, weights, and material specifications.
• Gas Turbine Specifications: Details on compressor type, combustion chamber, turbine type, and performance metrics.
• Solar Gas Compressors: Lists maximum pressure ratings, flow, and total head for various compressor families.

Compressor impellers are designed for conservative stress levels and are suitable for sour gas applications. Each impeller is proof tested to 115% of its maximum mechanical speed after machining.

The rotor assembly includes stub shafts, impellers, rotor spacers, and a centerbolt. Components are individually balanced and aligned for concentricity. The assembly is clamped with a centerbolt, allowing easy disassembly and reuse of impellers, enhancing economic feasibility and minimizing downtime.

The compressor casing is a vertically split "barrel" design, consisting of suction and discharge end caps and a centerbody. End caps contain service ports for oil and gas supply and discharge.

The module includes centrifugal compressors mounted on a structural steel base, forming a continuous base plate with the driver skid for subsystem installation.

A common lube oil system is used for the gas turbine, gearbox, and compressor modules.

The system includes seal gas and separation gas systems to maintain barriers between process gas, compressor bearings, and lube oil. The seal gas system uses primary and secondary seals to prevent gas escape, with flow rates metered by pressure drop across orifices. Separation gas provides a barrier between lube oil and dry gas seals.

Compressor casings and end caps undergo hydrostatic pressure testing per API 617 at 1.5 times the maximum casing design pressure for 30 minutes.

Solar’s standard shaft interconnect is a dry coupling.

Preliminary alignment of the drive train is performed at the factory to simplify final field alignment.

The Mars gas turbine mechanical-drive package is designed for various driven equipment, including pumps and compressors. It offers unitized and non-unitized packaging options, with unitized packages providing integrated controls and lubrication systems.

A gearbox can be provided for compressor set and mechanical drive applications, designed for continuous-duty operation and matching turbine output speed to compressor operating speed. It is designed according to ANSI/AGMA standards.

The document describes the lubrication and temperature monitoring systems for gearboxes and bearings in turbine-driven machinery. Each gearbox is lubricated by forced-fed oil from the turbine, and temperatures are monitored using simplex resistance temperature devices (RTDs) at radial and thrust bearings. The monitoring system connects to one RTD per bearing, with spare circuits available.

This gearbox is designed to increase the output speed of a driving compressor to match the operating speed of a driven compressor. It rotates counterclockwise when viewed from the exhaust end and is mounted on the driven compressor skid.

This gearbox reduces the turbine's output speed to optimize the driven equipment's operating speed. It also rotates counterclockwise when viewed from the exhaust end and is mounted on the driven equipment skid.

The document provides specifications such as weight, inspection intervals, compliance with API 613, and ratings according to ANSI/AGMA standards. Vibration monitoring options include acceleration and displacement probes.

The start system initiates engine rotation using either a direct-drive AC starter motor with a variable frequency drive (VFD) or an optional pneumatic start system. The VFD controls the starter motor's speed, while the pneumatic system uses process gas or compressed air.

This system includes a squirrel cage induction motor and a VFD, which regulates voltage and frequency. The motor provides high starting torque and is explosion-proof. The VFD is capable of extended purge cycles and is installed in non-hazardous locations.

This optional system uses air or natural gas to power a pneumatic starter motor, which transmits power to the gas turbine via an overrunning clutch.

The fuel system controls ignition and fuel flow, with configurations for conventional and SoLoNOx combustion. It includes components like fuel control valves, shutoff valves, and fuel injectors. The system ensures stable combustion and minimizes emissions.

Specifications include acceptable gas fuels, pressure and temperature ranges, and compliance with NACE standards. The system features pneumatically actuated shutoff valves and precise control via DC motor-driven actuators.

• Fluid: Clean-Dry Air
• Air Quality: Particle size should not exceed 10μm, with oil or hydrocarbon content not exceeding 1 ppm. Dew point at line pressure should be at least 6°C below the minimum temperature exposed.
• Pressure Range: 689 to 1379 kPag (100 to 200 psig)
• Pilot Air Filter: 10 micron
• Construction Materials: 316L Stainless Steel for piping, manifolds, and tubing

• ES 9-98: Fuel, Air, and Water for Solar Gas Turbine Engines
• ES 1593: NEC Compliance Guidelines
• ES 1762: Electrical Systems Standards for Hazardous Areas
• ES 2201: Auxiliary Service Air

• General Description: Circulates oil under pressure to the gas turbine and driven equipment. Includes components like oil tank, lube oil pumps, filters, and temperature regulators.
• Lube Oil: Customer furnished, petroleum base or synthetic oil with viscosity grade C32 or C46 recommended.
• Main Lube Oil Pump: Engine-driven rotary screw type with a flow of 2570 lpm.
• Pre/Post Lube Oil Pump: AC motor-driven centrifugal type for starting and cooling.
• Backup Lube Oil Pump: DC motor-driven centrifugal type for emergency conditions.
• Duplex Lube Oil Filter System: Includes a filter transfer valve and differential pressure indication with alarm.
• Lube Oil Vent Coalescer: Removes oil vapor from the lube oil tank vent airflow.
• Optional Features: Offskid oil cooler, oil tank heater, stainless steel components.

• Main Lube Oil Pump: Discharge pressure of 607 kPag.
• Lube Oil Cooler: Air-to-oil type, designed for specific heat loads and ambient temperatures.
• Lube Oil Tank Capacity: 3406 L (900 gal).
• Construction Materials: 316L Stainless Steel for piping, optional for other components.

• General Description: Controls and monitors the turbomachinery package, based on Rockwell Automation/Allen-Bradley platform.
• System Architecture: Includes ControlLogix controller, RSLogix 5000 software, Flex I/O modules, FieldMonitor vibration system, and ControlNet network.
• Backup Shutdown System: Provides additional protection by shutting down the package safely in case of primary control system malfunction.

The document provides a detailed description of the monitoring and control systems for turbomachinery packages, specifically the Mars 90 and 100 Compressor Set and Mechanical Drive. It outlines the components, configurations, and functionalities of the control systems, including both onskid and offskid configurations.

The control system utilizes a ControlNet network for primary communications, with hardwire backup for critical circuits. Key components include the TT4000S and TT4000 operator panels, variable speed frequency drives, and various sensors and monitors. The system is designed to operate in hazardous areas, adhering to NEC Class 1, Division 2, or CENELEC Zone 2 standards.

• Controller: The ControlLogix controller, using RSLogix 5000 software, provides primary control and supports ladder and function block programming.
• ControlNet 1.5: A deterministic network operating at 5 Mbps with redundant cabling, supporting a maximum length of 800 meters.
• Input/Output Modules: Flex I/O modules interface with package instrumentation, handling various input and output types.
• Vibration Monitoring System: Utilizes Bently Nevada's 1701 FieldMonitors for vibration detection and alarm configuration.
• Backup Shutdown System: Ensures safe shutdown in case of primary system failure, monitored by watchdog circuits.
• Fire and Gas System: The Eagle Quantum Premier system detects and responds to fire and gas threats within enclosures.
• Control System Power Supplies: Operates on 24 VDC power, with a standard battery charge system providing 120 VDC.

• Starting and Loading: Initiates with a Start command, involving a sequence of tests and operations to safely start the gas turbine.
• Steady-State Control: Maintains equipment within specified conditions, with temperature and speed monitoring.
• Stopping: Includes manual and automatic shutdown procedures, with cooldown and emergency stop options.
• Vibration and Temperature Monitoring: Continuous monitoring at key locations, with specific sensors and thermocouples.

Provides extensive data collection and display capabilities, with two versions: TT4000 and TT4000S. The TT4000 offers full features, while TT4000S is designed for onskid use with limited graphics.

Includes discrete event logs, analog data logs at various intervals, and trigger logs for specific events. The system supports multiple languages and offers customizable display screens.

The Turbotronic 4 system is fully programmable in the field, requiring RSLogix 5000 software and appropriate hardware.

The system supports various engineering units for display, including metric and English options.

This document provides detailed specifications and guidelines for the Mars 90 and 100 Compressor Set and Mechanical Drive, focusing on control and monitoring systems, enclosure features, and safety mechanisms.

• Control Consoles: Dimensions and weights for one-bay and two-bay control consoles are provided, with specifications for supervisory interface modules including ControlNet, Ethernet, Data Highway Plus, and Modbus.
• Package End Devices: Includes transmitters, switches, thermocouples, RTDs, and proximitors.
• Engineering Specifications: Covers fusion welding, NEC compliance, electrical systems standards, and cable installation in hazardous areas.

• Process Control: Options for unit control based on gas compressor parameters with local and remote setpoint adjustments.
• Suction and Discharge Pressure Monitoring: Includes transmitters for pressure and flow with alarm and shutdown capabilities.
• Surge Detection and Control: Systems to detect and prevent compressor surge through control algorithms and hardware like surge control valves.
• Vibration and Temperature Monitoring: Proximity probes and RTDs for monitoring compressor bearings with alarm and shutdown levels.

• General Description: Weatherproof, insulated, and sound-attenuated enclosure with access doors and maintenance features.
• Ventilation and Temperature Control: Includes silencers, a single-fan ventilation system, and high-temperature alarms.
• Pressurization and Lighting: Positive pressure system to prevent hazardous atmosphere ingress and fluorescent lighting for interior illumination.
• Sound Attenuation: Designed to comply with OSHA standards for noise reduction.
• Fire and Gas Detection System: Advanced system for monitoring and extinguishing fires, with infrared detectors and manual override options.

The fire detection system transmits electrical signals to the control panel to activate alarms and suppression systems. The system includes multi-spectrum IR flame detectors, thermal detectors, and IR gas detectors. Gas detectors are placed at the turbine enclosure's air inlet and exhaust to monitor combustible gases continuously. The system ensures safety before starting the turbine engine and triggers alarms if the gas monitor fails.

• Enclosure Configuration: Options to house both the gas turbine and driven equipment or only the turbine.
• Dual Fan Ventilation: A dual AC motor-driven fan system is available, with independent power sources required for CE certification.
• Dust Protection System: Single-stage filters with differential pressure alarms prevent dust entry.
• Dust and Moisture Protection System: Two-stage filters with moisture eliminators and alarms protect against dust and water.
• Standby Lighting: Provides emergency lighting powered by the package battery system.
• Door Open Alarm: Initiates an alarm if enclosure doors are not securely closed.
• CO2 Fire Suppression System: Includes primary and secondary distribution systems to maintain CO2 concentration for 20 minutes.
• Water Mist Fire Suppression System: High-pressure system for 10 minutes of water mist discharge.
• Fire Cylinder Cabinets: Weatherproof cabinets for outdoor installations with manual pull levers.

• Ventilation Fan Motor Voltage: Options include 380-575 VAC.
• Lighting Voltage: Primary at 220 VAC or 110 VAC; standby at 120 VDC.
• Sound Pressure Level: Estimated at 85 dBA.
• Roof and Wind Load: Maximum roof load of 244 kg/m² and wind velocity of 193 kph.
• Weights: Gas turbine enclosure weighs 5880 kg; compressor enclosure weighs 3560 kg.
• Fire Suppression Compliance: CO2 system complies with NFPA 12 and USCG CFR 46; water mist system complies with NFPA Code 750.

• General Description: Ensures a steady flow of clean air for turbine combustion. Various filtration systems are available for different environments.
• Prefilter and Barrier Inlet Air Filter: Suitable for moderate environments with moisture eliminators and high-efficiency filters.
• Self-Cleaning Barrier Type Air Filter: Designed for extreme environments, requires a cleaning air supply.
• Marine/Offshore High Velocity Air Filter: Suitable for offshore applications, removes salt, water, and particulates.
• Offshore/Coastal Medium Velocity Air Filter: High-efficiency system for extreme conditions, includes HEPA filters.
• Insect Screens: Optional screens to prevent insect entry, removable in cold weather.
• Air Inlet Gas Detection: Integrated with the fire and gas system for enclosed packages.
• Air Inlet Silencer: Optional silencers to reduce noise levels.
• Air Inlet Ducting and Support: Optional support structures and ducting available.

• Pressure Drop: Less than 102 mm H2O with a clean filter.
• Ducting Loads: Should not exceed 91 kg in any direction.
• Prefilter and Barrier Inlet Air Filter: Airflow of 33.7 m³/s with specified dimensions.

• Quality Assurance: Solar Turbines is ISO 9000 certified, with a focus on engineering, manufacturing, and testing standards. They offer project-specific QA documentation and involve customers in the QA process through an Inspection and Test Plan (ITP).
• Testing: Factory testing follows Solar's specifications, including a three-phase test program for control systems and package integration. Acceptance testing covers starting cycles, lubrication, vibration, power, and heat rate measurements.
• Compressor Testing: Includes hydrostatic testing and aerodynamic performance validation.
• Acceptance Test Data: Reviewed by Test Engineering and provided to customers, including fuel consumption and operating values.

• Preservation: Long-term preservation is needed for storage over six months or sea transport. Short-term preservation is for less than six months and non-sea transport.
• Site Requirements: Minimal preparation needed; self-contained systems for starting, fuel, and control.
• Mechanical Installation: Guidelines provided in TPIM-1010, with emphasis on correct mounting and alignment tooling options.
• Documentation: Includes drawings, manuals, and optional torsional and lateral analysis reports.

• Solar complies with various international standards, including NEC, CEC, CE Mark, IEC, and AS/NZS 3000.

The document outlines various certifications and standards relevant to Solar Turbines' products. It mentions the National Association of Corrosion Engineers (NACE) and several OSHA-approved Nationally Recognized Testing Laboratories (NRTLs) such as Underwriters Laboratories (UL), Factory Mutual (FM), and Canadian Standards Association (CSA). The NEC classifies hazardous sites into Classes, Divisions, and Zones, with Class I and Division 1 and 2 being significant for flammable gases.

Solar complies with the Canadian Electrical Code (CEC) for installations requiring certification, adhering to standards from CSA, ENTELA, and UL.

For CE Mark certification, Solar follows EU directives like ATEX, Pressure Equipment, Machinery Safety, Electromagnetic Compatibility, and Low Voltage Directives. Det Norske Veritas (DNV) assists in compliance, and Solar self-certifies for CE Mark requirements, ensuring design and manufacturing adhere to CENELEC and CEN standards.

IEC 61508 standardizes the assessment of functional safety for safety-related systems, categorizing safety integrity levels (SIL1 to SIL4) based on potential risks.

Solar adheres to standards from authorities like DNV, ABS, Lloyd’s Register, and Bureau Veritas for offshore marine certifications, with specific procedures for design verification and manufacturing surveys.

Solar offers comprehensive construction services, including feasibility studies, design, procurement, and installation. Customer services provide technical support, training, and maintenance, while contract power and leasing services offer various financing options.

The document includes a conversion chart for various units and a list of abbreviations used throughout the text.