Chapter 2 Maintenance PDF

 

GE Aero Energy Products A GE Power Systems Business

Chapter 2 Table of Contents

Chapter 2, Maintenance Table of Contents Title

Page

General Information ................................................................................................................................2-1-1 ................................................................................................................................2-1-1 Scope ....................................................................................................................................................... 2-1-1 General Maintenance Concept ................................................................................................................ ................................................................................................................2-1-1 2-1-1 Servicing ................................................................................................................................................. 2-2-1 Preventive Maintenance ..........................................................................................................................2-2-1 ..........................................................................................................................2-2-1 Preventive Maintenance Procedures .......................................................................................................2-2-5 .......................................................................................................2-2-5 Required Lubricants and Consumables................................................................................................. Consumables ................................................................................................. 2-2-10 Troubleshooting ...................................................................................................................................... ......................................................................................................................................2-3-1 2-3-1 Prime Mover ........................................................................................................................................... ...........................................................................................................................................2-3-1 2-3-1 Generator ................................................................................................................................................ 2-3-1 Ancillary Equipment ...............................................................................................................................2-3-1 ...............................................................................................................................2-3-1 Repairs and Adjustments ........................................................................................................................2-4-1 ........................................................................................................................2-4-1 Prime Mover ...........................................................................................................................................2-4-1 ...........................................................................................................................................2-4-1 Generator ................................................................................................................................................ 2-4-1 Engine to Generator Alignment ..............................................................................................................2-4-1 ..............................................................................................................2-4-1 Ancillary Equipment ...............................................................................................................................2-4-7 ...............................................................................................................................2-4-7 Special Tools................................... ................. .................................... .................................... .................................... .................................... .................................... ................................ .............. 2-4-8

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Chapter 2, Section 1 General Information SCOPE  The following maintenance instructions provide a guide to conduct operator-level maintenance of the GE Energy Model TM2500 MGTG set. Maintenance information for the the vendor-supplied equipmen equipmentt is  provided  provi ded in Chapter Chapter 5 of this manual. manual.

GENERAL MAINTENANCE CONCEPT “On-Condition” Maintenance The maintenance concept for the turbine-driven generator is generally referred to as on-condition maintenance, which eliminates scheduled overhaul overhaul based on operating hours. Under the on-condition concept, ancillary turbine-driven equipment is inspected on a regular schedule and repaired as necessary to restore the unit to operational serviceability. See Table 2.1, Turbine Engine On-Condition Maintenance  Inspection/Check  Inspection /Check Schedule; Schedule; Table Table 2.2, Generat Generator or Inspecti Inspection on Int Interval ervals; s; and Table 2.3, Ancillary Equipment  Maintenance  Maint enance Schedule Schedule in Section 2 of this chapter.  chapter.   Two factors determine the extent of repairs under this concept: 1) Correction of the primary cause of failure and/or discrepancy and any resultant secondary damage. 2) Replacement or repair of parts that do not meet meet established inspection criteria defined in the the technical manual.

On-Site Maintenance On-site maintenance falls into the categories of preve of preventive ntive scheduled  scheduled maintenance and corrective corrective   unscheduled maintenance.

   Preve  Preventive ntive maintenan maintenance ce is  is described as scheduled maintenance based on operating hours or those

•

scheduled to coincide with some event, or a combination of both, or as a result of monitoring conditions.

  Corrective maintenance is maintenance is described as unscheduled maintenance performed to correct a

•

malfunction as a result of failure or impending failure detected by inspection and/or condition monitoring. During operation, the following items are monitored: monitored: gas generator speed, power turbine speed, gas generator and exhaust gas temperature, engine and driven equipment vibrations, oil pressure, oil temperature, and normal and peak operating times. Under the on-condition maintenance philosophy, scheduled maintenance actions shutdown can be accomplished concurrently at intervals of 4000 hours or 6 months and 8000 hoursrequiring or 12 months.

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Chapter 2, Section 2 Servicing PREVENTIVE MAINTENANCE The schedules in Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule; Table 2.2, Generator Inspection Intervals; and and   Table 2.3, Ancillary Equipment Maintenance Maintenance Schedule  Schedule  describe the recommended inspection intervals intervals for the TM2500 MGTG set. Recommended maintenance level codes are defined as (1) Level I, Minor Repair; (2) Level II, Heavy Repair; and and (3)  (3) Level III,  Restoratio  Resto ration. n.   Maintenance level codes are assigned assigned based on the degree of complexity.

Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule

Item   Item

Inspection Check Required   Required

Inspection Frequency   Frequency

Maint. Level   Level

1

Engine Oil Level

Daily

I

Check oil level and check system for oil leaks.

2

General Condition of Engine

Weekly

I

Inspect external engine components for security of installation.

3

Engine Mounts

500 Hours

I

Check for security, cracks, and isolation deterioration.

4

Electrical Harness Leads & Cables

500 Hours

I

Check for security; check ignition leads and thermocouple harness for burning or chafing.

5

Control Linkage

500 Hours

I

Check for freedom of movement, rod end wear, and security.

6

Magnetic Plugs

500 Hours or after internal failure

I, II, III

Continuity check for particle accumulation. Should also be checked after internal engine failure.

7

Engine Plumbing

500 Hours

I

Check fuel and oil plumbing line to and on engine for security, chafing, and leaks.

8

Lubricating Oil

1 Month or 700 hours, or I, II after oil change

Have oil sample analyzed.

9

Compressor Cleaning

As required

I

Water wash (refer to procedures in this chapter and section).

10

Fuel Filters

2000 Hours or as

I

Check for cleanliness and damage.

Remarks   Remarks

required by Delta P

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Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule (Cont) Inspection Check Required   Required

Inspection Frequency   Frequency

Maint. Level   Level

Remarks   Remarks

11

Thermocouple Ring

4 4000 000 Hours

I

Check thermocouple calibration.

12

Mechanical Linkages

4000 Hours

I

Check for wear.

13

Engine Inlet & Compressor Assy.

4000 Hours

I, II, III

Maintenance level depends on inspection findings.

14

Engine Oil Filter

6 Months or 4000 hours, or as required by Delta P

I

Remove, inspect, replace filter.

15

Igniters & Liner Supports

6 Months or 4000 hours

I

Inspect at 4000 hours, then every 12 months or 8000 hours.

16

Thermocouples & Wiring 6 Months or 4000 hours

I, II

Inspect first at 500 hours, then 1000 hours, then each 4000 hours.

17

Turbine First Stage

6 Months or 4000 hours

I, II

Inspect first at 500 hours, then 4000 hours or 6 months.

18

Combustor

6 Months or 4000 hours

I, II

Maintenance Level III depends on inspection findings.

19

Fuel Nozzles

6 Months or 4000 hours

I

Inspect for carbon and wear at 500 hours, then at 4000 hours.

20

RPM & Temperature Control

6 Months or 4000 hours

I, II

Check for accuracy. Calibrate if necessary.

21

Combustible Gas Detector Calibration

6 Months or 4000 hours

I

Calibrate in accordance with instructions in Wilson Fire and Gas

Item   Item

Protection System manual in Chapter 5. 22

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Engine-to-Generator Alignment

12 Months or 8000 hours

I

Check for accuracy. Adjust if necessary. Refer to Installation Manual for procedures.

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Table 2.2, Generator Inspection Intervals

Item   Item

Inspection Check Required   Required

Inspection Frequency   Frequency

Maint. Level   Level

1

Lube Oil Level

Daily

I

Check reservoir sight gauge for positive flow. flow. Use oil recommended in Table 2.4.  2.4. 

2

Bearing Drains

Daily

I

Check that flow is being maintained.

3

Vibration Signatures

Weekly

I

Check Bently Nevada gauges for vibration measurement.

4

Rotor Winding Insulation

1000 Hours, or as required

I

Requires 500V megohmmeter. Refer to FKI manual in Chapter 5 for proper procedure.

5

Lubricating Oil

6 Months or 4000 hours, or when

I

Have oil samples analyzed.

Remarks   Remarks

oil is changed 6

Oil Pump Coupling

4000 Hours

I

Visually inspect for separation of rubber-to-metal bond.

7

Bearings

12 Months or 8000 hours

I, II

Maintenance level depends on findings.

8

Instrumentation

12 Months or 8000 hours

I, II

Calibration of the Bently Nevada gauges, pressure, and temperature switches.

9

Bearing Insulation

12 Months or 8000 hours, or as required

I

Check resistance (refer to FKI manual in Chapter 5).

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Table 2.3, Ancillary Equipment Maintenance Schedule

Item   Item 1

Inspection Check Required   Required

Inspection Frequency   Frequency

Maint. Level   Level

Remarks   Remarks

General Conditions

Daily

I

General appearance and integrity of unit.

2

CO2 Level

Weekly

I

Check per Chapter 2, Section 2, CO 2  Weight and Pressure Check.  Check. 

3

Fluid Filters

3 Months or 2000 hours, or as required by Delta P

I

Check for blockage.

4

Mount/Piping/ Mount/Piping/Valves Valves

6 Months or 4000 hours

I

Check for leaks, cracks, and proper alignment.

5

Thermocouples

6 Months or 4000 hours

I

Check for secure connections.

6

Fluid Couplings

6 Months or 4000 hours

I

Check for leaks and system integrity.

7

Control Panel

6 Months or 4000 hours

I

Check for cleanliness and secure electrical connections.

8

Air Inlet Filters

6 Months or 4000 hours, or as required by Delta P

I

Check for cleanliness.

9

Generator Lube Oil System Auxiliary Lube Oil Pump

6 Months or 4000 hours

I

Replenish grease cups or fittings as required per maintenance instructions.

10

Ventilation Fan Bearings

6 Months or 4000 hours

I

Replenish bearing lubricant per maintenance instructions in Chapter 5.

11

Batteries & Battery Chargers (if provided)

6 Months or 4000 hours

I

Replenish electrolyte, check specific gravity, clean battery case. Adjust float-and-equalizing potentiometers, as required.

12

Optical Flame Detectors

6 Months or 4000 hours

I

Refer to periodic checkout procedure in the Wilson manual in Chapter 5.

13

Control Panel Instruments

1 Year or 8000 hours

I, II

Check for proper calibration.

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Table 2.3, Ancillary Equipment Maintenance Schedule (Cont)

Item   Item

Inspection Check Required   Required

Inspection Frequency   Frequency

Maint. Level   Level

Remarks   Remarks

14

Electrical Sensors and

1 Year or

I, II

Check for proper calibration.

Transducers

8000 hours

Gas Sensors (Fire and Gas Protection System)

To be determined by I, II owner

15

Refer to Wilson manual in Chapter 5 for calibration procedures and criteria.

PREVENTIVE MAINTENANCE PROCEDURES This section describes the procedure to perform the Level I on-site external preventive maintenance. Preventive maintenance procedures for vendor-supplied equipment are provided in Chapter 5.

Turbine Compressor Cleaning The water wash provisions are designed to meet the minimum water wash requirements given in the GE manual,  GEK-97310, and to minimize exposure of service personnel to concentrated cleaning solvents. manual, For specific guidelines on cleaning scheduling and recommended solvents, see GE manual,  manual, GEK-97310, in Chapter 5 of this manual.

Water Wash, Off-Line Off-line water wash requires two maintenance persons to be equipped with a two-way communications link that permits them to communicate communicate easily while the turbine is being motored. Compressor cleaning shall be carried out in the following steps: Disconnect the discharge pressure sensing line from the compressor casing before performing off-line water wash. Failure to disconnect the line may permit soap and water to accumulate in the line, which can result in subsequent hot starts with possible damage to the turbine hot-section components, or cause false signals from the discharge pressure transducer.

  1.

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Disconnect the discharge pressure-sensing line from the compressor casing. Plug the disconnected end to prevent water from entering the line.

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Chemicals used in compressor cleaning solution are volatile, toxic, and highly flammable. Follow the warnings given iin n GE manual, GEK- 97310, regarding the handling handling of cleaning solvents. Failure to follow guidelines could result in fire or explosion with subsequent injury to personnel or damage to equipment.

  2.

If ambient temperatures justify the use of antifreeze, prepare approximately 80 gallons of water/antifreeze solution. solution. (See GE manual, manual,  GEK-97310, for the mixing ratio.)

Dispose of residual wastewater from water wash, in accordance with EPA and local environmental regulations. 

3.

Fill water wash tank with 38 gallons of potable water or water/antifreeze solution, as determined  by ambient ambient temperature temperature conditions conditions..

4.

Add 2 gallon of cleaning solution to water wash tank.

5.

Close tank fill and vent valves.

6.

Verify that the turbine control panel (TCP) is energized and functioning normally.

7.

Turn Turbine Control  switch  switch to Water Wash. Wash. Push and hold turbine turbine Water Wash switch, Wash switch, located on turbine inlet porch. porch. The starter will engage and begin to crank the turbine. turbine.

8.

Once turbine cranking begins, the air valve will pressurize the tank and the inlet valve to the turbine wash manifold will open automatically. a utomatically.

9.

Hold Water Wash switch Wash switch in depressed position until all cleaning solution is used up.

10.

Allow turbine to coast to a stop. Wait 10 10 minutes minutes after turbine has sstopped topped before rinsi rinsing. ng.

11.

Rinse. Fill tank with 40 gallons of potable potable water or antifreeze/water antifreeze/water solution and repeat steps 5–9, above, at least three times.

12.

Blow residual water from turbine inlet nozzle manifold with compressed air.

13.

Shut off compressed air and examine turbine inlet. If not cleaned cycle.

14.

Operate Turbine Control  switch  switch to Hi to Hi Crank  Crank  to  to initiate a high-speed purge purge cycle. This purge cycle should blow most residual water out of the turbine.

15.

Remove the plug installed installed in the end of discharge pressure sensing sensing line in step 1 of this pro procedure. cedure. Reconnect the compressor discharge pressure (CDP) sensing line to compressor casing port.

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If turbine is too wet to start, check the CDP transducer and sensing line for water. Remove all water prior to attempting a fired start. 

place Turbine Control  switch  switch in Hi in Hi Crank Crank to initiate Note  If turbine fails to start on first attempt, place an additional high-speed purge cycle to dry turbine sufficiently to permit ignition. 16.

Start turbine and operate it at idle (gas generator speed of 5000–5500 5000–5500 rpm) for 5 minutes to dry it.

Fluid Filter Element Inspection and Replacement

Synthetic lube oil contains tricresyl phosphate, which is highly toxic and operates at high temperature and pressure. 

Fuel system maintenance should be performed only when the turbine is shut down. Exercise extreme care when servicing servicing fuel or lube oil system. Fire, explosion, or serious injuries co could uld occur. 

1.

Disconnect power for the turbine-generator lube oil cooler at the motor control center (MCC).

2.

Isolate filter assembly by closing all upstream and downstream valves in designated system lines. This will prevent contamination of remainder of system and minimize the need to bleed air from the system lines.

Wear goggles or similar eye protection when loosening lube oil system fittings, as residual pressure may be present. Do not smoke or carry an open flame or source of sparks when servicing fuel system. 

3.

Loosen vent plug on top of filter head assembly. This will relieve any residual pressure in filter assembly.

4.

Remove the drain plug from bottom of filter filter bowl bowl and allow fluid to drain into container provided. Remove vent plug, if necessary, to permit complete drainage of filter.

5.

Loosen and remove the knurled ring that clamps the filter bowl to the filter head assembly. Then remove the filter bowl, clamping ring, and filter element.

Note  Filter assemblies come in two two types. One type uses a through-bolt and/or nut arrangem arrangement ent to attach the filter bowl to the filter head. Other filter assemblies include a clamping arrangemen arrangementt or a

threaded filter head.

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6.

Examine filter element for damage or evidence of collapse, and observe the amount of dirt and debris entrapped in element. Check element gaskets gaskets for damage and proper seating. seating. Replace excessively dirty or damaged filter elements.

7.

Examine filter element bowl and head assemblies for damage or wear. Check all O-rings and gaskets for wear, damage, hardening, hardening, or cracks. Replace all seals, gaskets, and and O-rings.

8.

Clean filter bowl and filter gasket surfaces of filter head assembly with diesel fuel or a similar solvent that will not harm gaskets.

9.

Install filter bowl assembly with a new filter element, if necessary, and new seals. Install and tighten filter bowl drain plug, and loosely install vent plug into vent port in filter head assembly.

10.

Open valves in flu fluid id system system that were closed closed in step 2 of this this procedure. procedure. If necessary, activate the system pump motor to provide fluid flow into into filter assembly. Should fluid seepage occur, tighten filter assembly vent plug.

Dispose of contaminated fluids, in accordance with EPA and local environmental regulations. 

11.

Wipe up any spilled fluid prior prior to restoring the TM2500 TM2500 MGTG MGTG set to service. service. Check filter filter assembly for leaks. Eliminate leaks by tightening loose fittings. Confirm manual drain valve is closed.

12.

Restore power to the pump motor motor by turning switches switches to their normal settings at the MCC.

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CO2 Weight and Pressure Check The following procedure outlines the method to check the weight and pressure of the CO 2 in each bottle. For liquid level indication, charts, and tables referenced in this procedure, see the Wilson Fire & Gas Protection System Manual,  Manual, CO2 Systems  Systems section,  section, in Chapter 5 of this manual. 1. Use an accurate Fahrenheit thermometer to read and record the ambient temperature temperature for use use in converting the CO2 level to a weight measurement, and determining the acceptable minimum CO 2   pressure  press ure in each bottle bottle.. 2. To determine the CO2 level in each bottle, use the magnetic float/dipstick indicator as follows: a. a.   Remove the chained cap from the liquid level indicator at the top of the CO 2 bottle.  b.  b.   Lift the level indicator dipstick upward, until a sharp magnetic “tug” is felt on the dipstick. c.

Read and record the level indicated at the interface between the dipstick and the fixture.

d. Push the dipstick back back into the retainer and replace the cap. 3. Convert the level indication to pounds of CO2 as follows: Note  To convert the level reading to its equivalent pounds of CO2, see the conversion chart attached to each new CO 2 bottle. For further information, refer to the chart in the Wilson Fire & Gas Protection System Manual .

a. a.   On the left-hand side of the conversion chart, find the CO 2 level recorded in step 2 of this  procedure.  proce dure.  b. Move aacross cross the chart chart to the ambient ambient temperature temperature point (as interpo interpolated lated between between th thee temp temperatur eraturee lines on the chart). c. c.   From the juncture of the line from the level reading to the temperature point, move downward to the bottom of the chart and record the pounds of CO 2 in the bottle. d.  d.  If the CO2 weight is less than 95% of the original fill weight as stamped on the cylinder nameplate, replace the cylinder with a fully filled and charged cylinder and send the old cylinder to an authorized filling station for leak inspection, maintenance, and refill. 4. Check the CO2 cylinder charge pressure as follows: a.

Read and record the CO2 cylinder pressure at the manifold pressure indicator.

 b.  b.   Refer to the Wilson Fire & Gas Protection System Manual, Manual, and  and compare the indicated pressure with the minimum pressure for the ambient temperature. c.

If the pressure is below the limit, replace the cylinder with a fully filled and charged cylinder, and send the old cylinder to an authorized filling station to be re-superpressurized and leak tested.

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REQUIRED LUBRICANTS AND CONSUMABLES Turbine Lube Oil The turbine engine requires lubricating oil conforming conforming to MIL-L-23699 or MIL-L-7808. This is a synthetic oil. A list of oils meeting these specifications specifications appears in Table 2.4, Required Lubricants and Consumables,  Consumables,  under “Turbine Lube Oil.”

Generator Lube Oil The generator lube oils listed in Table 2.4 have 2.4 have been recommended by FKI Rotating Machines for their turbine-driven generators. Contact FKI Engineering Department for alternate oils. oils.

Hydraulic Fluid The hydraulic system requires fluid meeting the requirements requirements of MIL-H-17672 and ISO-VG46. A mineral based, premium, premium, anti-wear anti-wear hydraulic hydraulic oil oil is supplied supplied from from th thee factory. factory. The prime prime fa factor ctor in the the sele selection ction of hydraulic fluid is the oil temperature extremes that will will be experienced in service. These extremes will govern the selection of a hydraulic fluid with the most suitable suitable temperature/viscosity characteristics. characteristics. When considering the suitability of a particular hydraulic fluid or for applications near the extremes of viscosity/ temperature limits, consult the fluid manufacturer. manufacturer. As a minimum, hydraulic fluids should fall within within the viscosity ranges listed in Table 2.4, Required Lubricants and Consumables.  Consumables.  Some fluids complying with the above specifications appear in Table 2.4 under 2.4 under “Hydraulic Fluid.”

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Table 2.4, Required Lubricants and Consumables

System Turbine Lube Oil

Specified Lubricant

Address

AeroShell Turbine Oil 500

Shell Oil Company 50 West 50th Street New York, NY 10020

Caltex RPM Jet Engine Oil 5

California Texas Oil Corp. 380 Madison Avenue New York, NY 10017

Mobil Jet Oil II Mobil RM 193 A-3

Mobil Sales and Supply Corp. 150 East 42nd Street New York, NY 10017

Stauffer Jet II (Castrol 205)

Stauffer Chemical Company 299 Park Avenue New York, NY 10017

Turbine Lube Chevron Jet Engine Oil 5

Chevron Research Company 555 Market Street San Francisco, CA 94120

Amoco Jet II

American Oil Company 500 North Michigan Avenue Chicago, IL 60611

Sinclair Turbo S Type 2

Atlantic Richfield Co. 875 North Michigan Avenue Chicago, IL 60611

Required Quantity   Quantity 150 gallons

Atlantic Richfield Co. Union Bank Building P.O. Box 2679 Los Angeles, CA 90054 Exxon Turbo Oil 2380

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Exxon Co., USA P.O. Box 2180, Room 2455 Houston, TX 77252-2180 (713) 656-5949

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Table 2.4, Required Lubricants and Consumables (Cont)

System Generator Lube Oil

Hydraulic Fluid

Specified Lubricant

Address

Caltex Regal R & 0.32

California Texas Oil Corp. 380 Madison Avenue New York, NY 10017

Castrol Perfecto N.A. Light

Stauffer Chemical Company 299 Park Avenue New York, NY 10017

Mobil DTE Light Mobil DTE 13

Mobil Sales and Supply Corp. 150 East 42nd Street New York, NY 10017

Shell Lowtherm 25 Shell Turbo T.32

Shell Oil Company 50 West 50th Street New York, NY 10020

Required Quantity   Quantity 215 gallons

Viscosity Ranges Maximum at Startup

4600 sSu (1000 cSt)

Normal Operating Range

66–464 sSu (12–100 cSt)

Optimum Operating Range

81–141 sSu (16–30 cSt)

Minimum Acceptable

60 sSu (10 cSt)

ARCO Duro AW-46

Atlantic Richfield Co. Union Bank Building

40 gallons

P.O. Box 2679 Los Angeles, CA 90054

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Texaco Rando HDAZ-32 (New York Air Brake Start Motors Only!)

Texaco Incorporated 2000 Westchester Avenue White Plains, NY 10650

Mobil DTE 25

Mobil Sales & Supply Corp. 150 East 42nd Street New York, NY 10017

Exxon Nuto H 46

Exxon Co., USA P.O. Box 2180, Room 2455 Houston, TX 77252-2180 (713) 656-5949

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These oils are not to be considered the only ones that may be used. Refer to the pertinent vendor material contained in Chapter 5 of this manual. Oil companies reserve the right to review their specifications specifications periodically. It is essential and the customer’s responsibility, responsibility, therefore, to verify oil specifications with the local oil supplier.

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The most significant item of these scheduled inspections is a turbine borescope check, which provides specific information on the condition of the engine’s engine’s compressor and hot-gas path. The turbine has a number of ports specifically located to facilitate borescope inspections. inspections. It is standard practice to monitor the condition of internal parts and schedule on-condition maintenance intervals based on borescope inspections. Overall maintenance is divided into three basic levels according to the level of complexity and shop capability.

On-Site External Maintenance - Level I This is the simplest level of maintenance and it encompasses the following two categories:

   Preve  Preventive ntive Maintenan Maintenance: ce: Tasks that are scheduled on the basis of equipment “run” hours or

•

calendar time.

  Corrective Maintenance:  Maintenance:  Tasks that are unschedu unscheduled led and performed to correct a malfunction.

•

On-site external maintenance includes all work on the outside of the equipment, plus scheduled inspections of turbine generator, cleaning (water wash), and changeout of gas generator turbine or components of driven equipment (when necessary).

Off-Site Maintenance - Level II (Medium Shop Shop Repair) This level of maintenance includes a complete teardown and rebuild of major components of the turbine generator.

Off-Site Maintenance - Level III (Extensive Shop Repair) This scope of work provides for all levels of maintenance, plus a complete repair of gas generator, power turbine, or driven equipment equipment parts. A test cell is required required for a Level III facility.

Maintenance Schedule  Normall maintena  Norma maintenance nce of the GE AEP turbin turbine-pow e-powered ered package package during during the initi initial al 3 years years of operation operation (at 8000 hoursNone per unit per year) will require onlyrequires a weekly visual inspection and driven equipment exteriors. of these inspections or tasks equ equipment ipment removal of or turbine disassembly. The weekly inspection will require approximately approximately one man-hour while the unit is in operation. The scheduled maintenance tasks are recommended at 6- and 12-month intervals, and can be performed in one 8-hour shift, requiring approximately 16 man-hours for the set of tasks on the turbine.

Note 

Do not fill the turbine lube oil reservoir past two-thirds full while the turbine is running. Overfilling will result in runover when unit is shut down.

Required Lubricants and Consumables See Table 2.4, Required Lubricants and Consumables, in Consumables, in Section 2 of this chapter for recommended list of lubricants and fluids used on the turbine-generator set. set. For acceptable equivalents, see vendor-provided instructions in Chapter 5.

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Chapter 2, Section 3 Troubleshooting

on this page is contained contained in Chapter 5 of this manual. Note  Vendor literature referenced on

PRIME MOVER Troubleshooting procedures for the prime mover are contained in Volume I of the General Electric On-Site Operation and Maintenance for General Electric TM2500 G Series and P Series Gas Generators and Gas Turbines, GEK- 97310.  97310.  For ancillary equipment, control system, and related troubles troubleshooting, hooting, refer to Chapter 4 in this manual.

GENERATOR Troubleshooting procedures for the FKI AC generator appear in the FKI the  FKI Operati Operating ng Machines Machines Installati Installation, on, Operation & Maintenance Manual.  Manual.  Refer to Section 7, Fault Finding, of Finding, of the FKI manual for troubleshooting information.

ANCILLARY EQUIPMENT Troubleshooting information for various external systems of the turbine-generator unit can be found in specific vendor literature and the GE Aero Energy Products drawings in Chapter 4.

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Chapter 2, Section 4 Repairs and Adjustments PRIME MOVER Repairs Repairs of the LM2500 Turbine Engine are covered in the GE On-Site GE  On-Site Operation and Maintenance Manual, GEK-97310, Volume GEK-97310,  Volume II, provided as part of Chapter 5 of this manual.

Adjustments Except for the variable stator control, very few adjustments are necessary for the turbine turbine engine. For adjustment to the variable stator control, see GE On-Site GE On-Site Operation & Maintenance Manual, GEK-97310, Volume II .

GENERATOR Repairs Procedures for repairing the FKI BDAX62-170ER AC generator can be found in the FKI the  FKI Instal Installatio lation, n, Operation & Maintenance Manual , provided in Chapter 5.

Adjustments A potential adjustment item is pilot pilot exciter remagnetization, described in Section 8 of the FKI manual. No other periodic adjustments of the generator are necessary.

ENGINE TO GENERATOR ALIGNMENT General The engine generator shafts shafts align with each other ther before operation. Accurate alignment extends the and service life of rotor the bearings beari ngsmust in both machines an and do ensures efficient, reliable operation. operation. Under normal operating conditions, optimum axial alignment reduces or eliminates loading on the thrust  bearings in both machines. machines. Laser alignment uses optical optical measurement techniqu techniques es that provide unequaled accuracy and repeatability. Optical measurement reduces many of the common errors associated with mechanical alignments that are affected by gravity. Technicians can quickly see graphical representations representations of the current alignment status and real-time effects of adjustments made to the turbine-generator unit. Professional reports can easily be generated by simply downloading laser alignment results to most  printers.

Note Engine to generator alignment is accomplished during setup of the MGTG, and complete instructions are provided in the Installation Manual for that purpose. Alignment procedures are repeated here in the event re-alignment becomes necessary at some point between setup and teardown,  providing trailer leveling leveling or docking have not been disturbed. disturbed. Otherwise, perform appropriate appropriate portions of the main trailer set up procedure in IT120 of the Installation Manual before proceeding with the engine to generator alignment described here.

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Adjustment Process The adjustment process starts with the measurement of existing shaft alignments between the generator and engine, and movement of the engine into position to correct misalignment. Measurements are made with a ROTALIGN® laser alignment system to identify parallel and angular offset values of the movable engine shaft as compared to the stationary generator shaft. Refer to Figure to  Figure 4.1, Parallel and Angular Angular Offset  Allrequired adjustment is accomplished by moving the enginegenerator platform shaft with jackscrews, wedges, shims,. as to align the engine shaft to the stationary Optimum offset and and angular alignment exists when the axes of engine and generator rotors coincide at normal operating temperatures. In the following procedures, the term “forward” refers to the direction toward the bellmouth end of the main trailer. GE Aero Energy Products (GE AEP) Technical Services has the required equipment and personnel familiar with conducting laser alignments. alignments. Please contact your GE AEP Technical Services regional service office for assistance in contracting their services.

Axial Alignment Axial loading on the engine thrust bearings can be greatly reduced or eliminated by ensuring that the engine and generator rotors remain separated at operating temperatures. Incorporate proper separation by installing the coupling with a prestretch that will allow its flexible diaphragm packs to reach their unflexed, unloaded states through through normal thermal expansion. expansion. The forward thrust capacity of the power power turbine thrust bearing is is approximately one-third of of that in the aft direction. Therefore, to avoid overloading the bearing in the forward position, use the forward thrust position as a datum point and calculate the coupling prestretch as equaling the algebraic sum of all thermal expansions from engine cold to engine hot (fully loaded) conditions. Proceed with axial alignment as follows: 1.  Position turbine shaft fully forward. 2.  Position generator shaft at the mid-point of its axial travel. 3.  Install coupling extension removed for transport (Figure 4.2) and secure turbine end of extension to the flexible coupling. At the generator end of the extension, temporarily insert undersized bolts or metal rod through at least two of the extension and generator flange bolt holes. Bolts or metal rod should be of sufficient diameter to prevent any sagging at the joint, while aallowing llowing the extension to move axially in relation to the generator flange. 4.  Using a feeler gauge, measure the gap between the face of the generator coupling flange and the extension flange. This measurement (prestretch) should equal .35 inch. 5.  Adjust engine position with clevis fore and aft jacking screws to obtain the required .35 inch gap. If required amount of adjustment exceeds the range of the jack screws, loosen generator mounting bolts, and with jack screws in the center of their travel,. move generator axially with a hydraulic jack until gap is near .35 inch. 6.  Tighten generator-mounting bolts and final adjust gap to .35 inch with jack screws. 7.

Secure extension flange to generator shaft flange.

Repeat this procedure as necessary until the reading remains unchanged after tightening all fasteners.

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Preparations for Laser Alignment Prepare engine and generator for alignment by disconnecting the engine exhaust diffuser to expose the engine/generator coupling flanges. Access to the coupling can be attained through the access hatch on the left side of the exhaust silencer trailer. The diffuser is heavy and will require two men to move the unit to the rear and to install temporary support. 

Laser Alignment The only laser alignment system currently approved for use on all LM packages is ROTALIGN® (a registered trademark of Pruftechnic Pruftechnic AG). ROTALIGN is preferred because because of its features. Use the information in this section in conjunction with the operating instructions provided with the ROTALIGN laser tool, to perform laser alignment of the LM2500. LM2500. Parallel  Parallel offset  refers  refers to the amount of misalignment between two shaft centerlines at the load the load flange. flange. The direction of this parallel offset is  perpendicular to the load centerline centerline (refer to to Figure4.1,  Figure4.1, Parallel and Angular Angular Offset). Offset).   Angular offset   refers to the amount of separation between two flange faces at the load flange. Parallel and angular offsets are specified in vertical and horizontal directions.

Figure 4.1, Parallel and Angular Offset

Tools and Equipment  Equipment  Refer to Table 4.1, Recommended Tools and Equipment for Alignment, for a description of the tools and equipment necessary to perform the alignment procedure. The tools and equipment equipment are depicted in the figures that follow this table.

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Table 4.1, Recommended Tools and Equipment for Alignment

Quantity

Description

1

Laser kit with 5-meter cable

1

Magnetic bolthole bracket (PN ALI.2.106)

1

Inside micrometer (STARRETT PN 128BZ) (optional)

1

Dial calipers, 0"–6" (0.001" gradations)

1

Feeler gauge

Desired Parallel and Angular Offsets  Offsets  Table 4.2, LM2500 Desired Parallel and Angular Offsets, lists the desired parallel and angular offsets and tolerances for the TM2500 package. These values are specified at the the load flange. The correct viewing viewing direction is looking at the load from the turbine. The position of the turbine with respect to the load is defined as follows: parallel (+) with the turbine centerline either above or right of the load centerline; and angular (+) with the flanges open at either either the top or the right side. (Mils is 1/1000th of an inch [0.001"]).

Table 4.2, LM2500 Desired Parallel and Angular Offsets

TM2500

Vertical Offset

FKI Generator 

Parallel Mils

Value/Tolerance Re-alignment tolerance

-77

±5 ±7

Horizontal Offset

Angular

Parallel

Angular

Mils

Mil s

Mils

-7

 

±5 ±6

0

±5 ±7

0

±5 ±6

Laser Alignment Procedure Perform the following steps to measure and adjust parallel and angular offset values of the turbine engine rotor shaft in relation to the generator shaft. Measurements are made from the stationary load (generator) flange, to the turbine coupling flange.

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Note Rotate generator shaft with chainfall and strap from bracket provided. To ensure readings are accurate, relieve tension on shaft and allow it to settle before each reading. 1.

Attach RO ROTALIGN TALIGN sensor to rear face of turbine coupling flange w with ith magnetic magnetic brack bracket. et. Positio Position n sensor for line-of-sight alignment with the laser through the coupling tunnel.

2.

Attach ROTA ROTALIGN LIGN laser at the forward face of the shaft coupling coupling flang flangee with magnetic bracket. Position and test line-of-sight alignment with the sensor.

3.

Connect RO ROTALIGN TALIGN computer, select DIM Mode, and enter th thee follow following ing values: values: Refer to  Figure 8, Preset Dimensions Dimensions and Values. a.  b. c. d. c. g.

Coupling diameter = 16.375” Distance to left machine machine = 42” Distance to right machine = 102” RPM = 3600 RPM Machine 1 distance distance left to to right right foot foot = 118” Machine 2 distance, left left to right foot foot = 143”

4.

Set tool to Multipoint Multipo Moderotation and take from 20readings to 30 readings thro ugh 360º shaft rotatio rotation. n. Consistent degrees int of shaft between are not through critical.

5.

Select Coupling Coupling Mode to read shaft offset and and angular angular misalignment misalignment values Repeat Repeat step 4 and compare results for consistency. If readings are inconsistent, identify cause and repeat step 4.

6.

Select Move Move Mode and adju adjust st turbine turbine platform platform as required to to correct turbine shaft parallel an and d angular misalignment. Adjust the engine position by making equal shim changes at all engine  platform mount locations. locations.

7.

Replace and secure engine exhaust diffuser when alignment is complete.

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Figure 4.2, Preset Dimensions and Values

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ANCILLARY EQUIPMENT Repair Information for repair of the subsystems and components of the unit can be found in Chapter 5, Vendor  Data, and  Data,  and Chapter 4, Drawings of this manual. manual.

Adjustments The following adjustments should be made on an on-condition schedule or as needed to maintain equipment in proper working order. 1. Instruments and Indicators — Indicators — Instruments and indicators may need to be calibrated more frequently than listed in Table 2.3, Ancillary Equipment Maintenance Schedule, in Schedule,  in Section 2 of this chapter .  If a reading on the indicator is high or low and all other indications confirm proper operation, recalibration of suspect indicator is in order. 2. Transducers and Probes — Probes — Positioning of probes may need to be adjusted if indications appear to fluctuate or vary from the norm. Refer to proper vendor data contained in Chapter 5 of this manual. Also refer to GE AEP Flow and Instrument Diagrams (F&IDs) contained in Chapter 4 for set points of electrical instrument probes. 3.  Pressure  — Adjustments may need to be made on various pressure  Pressure and and Temperatu Temperature re Control Controllers lers — and temperature controllers to keep pressures and temperatures temperatures within normal range. Refer to GE AEP F&IDs contained in Chapter 4 for set points and to Chapter 5 for details of the various controllers. 4.  Equipment  Equipment Alignment  Alignment  —  — Realignment of equipment may need to be performed to compensate for normal wear. Excessive vibration or noise will generally indicate when this should take place. If vibration levels become too great, it is recommended recommended that an alignment check be made. Settling of the unit or foundation foundation can adversely affect machinery al alignment. ignment. Refer to Chapter 5 for tolerances tolerances of various vendor items. 5.  Air Filtr Filtration ation System System — The air filtration system is designed to operate for extended periods  between  betwe en mainten maintenance ance interv intervals. als. The tu turbine rbine enclosure enclosure is is equipped equipped with a different differential ial pr pressur essuree switch, which will trip an alarm on the turbine control panel in the auxiliary trailer control house when the air filtration system restriction reaches the point that maintenance is required. Maintenance of the air filtration system shall be carried out in accordance with the instructions  provided  provi ded by the air air cleaner cleaner manufactu manufacturer, rer, which which are are incl included uded in in Chapter Chapter 5 of this this manual. manual.

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6. Control System — System — The control system is designed to require little maintenance; however, there are two areas in the control system that require regular maintenance maintenance to ensure proper operation. These areas include the battery banks, with their attendant battery chargers, and the sensing switches, transducers, senders, thermocouples, and other sensing devices that are employed to monitor the operation of the units. 7.  Battery  Battery Banks Banks —  — The battery banks require periodic testing and replenishment of electrolytes, and inspection and cleaning of battery terminal connections connections and battery cases. The float-and-equalize voltage settings of battery chargers must also be checked and adjusted, adjusted, if necessary. Maintenance  procedures  proced ures and and recommen recommendatio dations ns for DC power power systems systems are are provided provided by the battery battery and battery battery charger instruction manuals included in Chapter 5.

SPECIAL TOOLS There is a requirement for special tools to provide Level I and Level II maintenance maintenance activities. These tools are listed in Table 4.3, Level I Maintenance Tools, and Tools,  and Table 4.4, Level II Maintenance Tools, and Tools,  and are recommended for customer-performed maintenance.

Calibration Equipment Refer to Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System Sensing  Devices,  Devic es, for  for a complete listing of special tools and equipment required for calibrating the control system sensing devices. Calibration equipment is not provided by GE AEP. This list is to aid the purchaser in  procuring  procu ring the the proper proper calibrati calibration on equipme equipment. nt. Equipment listed in Tables 4.3, 4.4, and 4.4, and 4.5 4.5 may  may not be provided by GE AEP in the basic scope of supply. Some of the equipment listed is not essential, essential, but is recommended for ease of service. Selected additional items may be purchased from GE AEP.

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Table 4.3, Level I Maintenance Tools Nomenclature

           

Quantity

Gauge, Immersion Igniter Plug

1

Wrench Set, Air Tube Coupling Sling, Gas Generator/Turbine Horizontal Lifting Adapter, Borescope Drive Wrench, Stator Vane Speed Sensor Wrench, Fuel Nozzle Borescope Set

1 1 1 1 1 1

 

Table 4.4, Level II Maintenance Tools Nomenclature

Quantity  Quantity 

Set, Jackscrew Puller, No. 5 Bearing Inner Race Wrench, High-Pressure Turbine Locknut

1 1 1

Stand, Vertical High-Pressure Turbine, Rear Main Fixture, Lift — High-Pressure Turbine, Rear Horizontal Wrench, Spanner—Oil Tube Fixture, Lift — Stage No. 1 High-Pressure Turbine Nozzle Puller, No. 5 Bearing Retaining Ring Fixture, Combustor Liner Horizontal Lifting

1 1 1 1 1 1

Wrench, Spanner —- No. 5 Bearing Retaining Nut Lift Eye, High-Pressure Turbine, Rear Aft Section Pusher, No. 5 Bearing Inner Race Wrench, Spanner, Hand Run-up Tool, Install/Remove Damper Sleeve Pins, Guide—Stage No. 2 High-Pressure Turbine Nozzle Adapter, Wrench

1 1 1 1 1 1 1

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Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System Sensing Devices Any test procedure that calls for rotating machinery to be in operation shall not be attempted without direct supervision by GE Aero Energy Products service technicians and/or representatives. Failure to comply with this warning could result in the equipment warranty being voided. 

Note  Test and calibration equipment with specifications equal to or better than equipment listed here may be substituted. Refer to manufacturer-provided publications, included in Chap Chapter ter 5 of this manual, for equipment specifications.  Nomenclature   Nomenclature

Part No.  No. 

Source/Manufacturer   Source/Manufacturer

Deadweight Tester (for testing pressure switches)

23-1 (or equivalent)

Chandler (or equivalent)

Hot-Oil Bath, electrically heated, with adjustable thermostatic temperature control, oil agitator, and calibrated thermometer (for testing temperature switches)

Various

Various

Digital Multimeter (two required)

8021B 177

Fluke Keithley

AC/DC Power Supply (two required)

6234A

Hewlett-Packard

Function Generator/ Frequency Counter

T86671

 © 

Volt-ohmmeter, 20,000 ohms/volt

260

Simpson

Oscilloscope, Dual-Channel 15 MHz

2213A/2215A

Tektronix

43027 Conductive PCB Shunt Bar (two may be required)

4962-005

 © 

Antistatic Protective Bag (two may be required)

4951-019

 © 

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Woodward Governor Company

Woodward Governor Company

Woodward Governor Company

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Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System Sensing Devices (Cont) Nomenclature   Nomenclature

Part No.  No. 

Source/Manufacturer   Source/Manufacturer

Jumpers, with insulated alligator clips

Various

Various

Ionization Detector Sensitivity Checker

SCU-9

Pyrotronics Pyr-A-Larm

Adapter Kit

SAU-2

Pyrotronics Pyr-A-Larm

Megohmmeter, 500 V–5 kV

21-158

Biddle (or equivalent)

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