Gek105054 LM2500 Plus O&M Manual

December 13, 2017 | Author: abelsg | Category: Gas Turbine, Gas Compressor, Turbine, Machines, Gases

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GEK 105054 VOLUME I

ON-SITE OPERATION AND MAINTENANCE MANUAL FOR GE

7LM2500-GK GV GAS GENERATORS AND 7LM2500-PK PV GAS TURBINES

INDUSTRIAL AERODERIVATIVE GAS TURBINES

GE Industrial AeroDerivative Gas Turbines Mail Drop S-133 One Neumann Way PO Box 156301 Cincinnati, Ohio 45215-6301, USA

GEK 105054

Highlights of Revision 1, Dated 15 April 2010 CHAPTER

LOCATION

DESCRIPTION OF CHANGE

Chapter 8

Paragraph 8-4.1.5

Updated rpm quantities in step d.

Chapter 10

Paragraph 10-4.5.2

Renumbered paragraph

App-A1

Entire

Updated entire Appendix 1

App-A2

Entire

Updated entire Appendix 2

GEK 105054 VOLUME I

ON-SITE OPERATION AND MAINTENANCE MANUAL FOR GE

7LM2500-GK GV GAS GENERATORS AND 7LM2500-PK PV GAS TURBINES

INDUSTRIAL AERODERIVATIVE GAS TURBINES GE PROPRIETARY INFORMATION The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, design, or configuration changes or to obtain any government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by U.S. export control laws. Unauthorized export or re-export is prohibited. All technical documentation and information contained herein have been developed and approved for use with GE engines and parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this document is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved parts and repairs.

COPYRIGHT 2010 General Electric Company, USA

GE Industrial AeroDerivative Gas Turbines Mail Drop S-133 One Neumann Way PO Box 156301 Cincinnati, Ohio 45215-6301, USA

15 APRIL 2009 Change 1 - 15 April 2010

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Foreword This two-volume technical manual provides on-site operation instructions and general maintenance procedures for the LM2500+ SAC Models GK and GV gas generators and Models PK and PV gas turbines. These instructions are not intended to cover all details or variations in equipment, or to provide for every contingency connected with installation, replacement, and maintenance. If more information is desired, or if problems arise which are not covered herein, contact GE M&I Customer Service.

LIST OF EFFECTIVE PAGES Dates of issue for original and change pages are listed below: Original ...... 0 ....... 15 April 2009 Change ...... 1 ....... 15 April 2010

Total number of pages in this volume is 376 consisting of the following:

Page No. Title A to B/(C Blank) i to xix/(xx Blank) 1-1 to 1-18 2-1 to 2-8 3-1/(3-2 Blank) 4-1 to 4-3/(4-4 Blank) 4-5/(4-6 Blank) 4-7 to 4-9/(4-10 Blank) 4-11 to 4-47/(4-48 Blank) 5-1 to 5-21/(5-22 Blank) 5-23/(5-24 Blank) 5-25 to 5-36 6-1 to 6-13/(6-14 Blank) 7-1 to 7-34

A

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Page No. 8-1 to 8-5/(8-6 Blank) 9-1 to 9-56 10-1 to 10-47/(10-48 Blank) 11-1 to 11-10 12-1 to 12-5/(12-6 Blank)

Change No. 1 0 1 0 0

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

List of Effective Pages (Cont.) Page No. APPENDIX A A-1/(A-2 Blank) A-3 to A-16 A-17 to A-23/(A-24 Blank) A-25 to A-26 A-27 to A-28 A-29 to A-33/(A-34 Blank) A-35 to A-37/(A-38 Blank) ADDENDUMS A-1/(A-2 Blank) A-3 to A-5/(A-6 Blank) B-1/(B-2 Blank) B-3 to B-7/(B-8 Blank) C-1/(C-2 Blank) C-3 to C-5/(C-6 Blank) D-1/(D-2 Blank) D-3 to D-5/(D-6 Blank)

Change No. 0 1 1 0 0 0 0

0 0 0 0 0 0 0 0

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

B/(C Blank)

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents Page Chapter 1

Chapter 2

Introduction .........................................................................................................

1-1

1-1

PURPOSE AND SCOPE OF TECHNICAL MANUAL .........................

1-1

1-2

ARRANGEMENT AND USE OF TECHNICAL MANUAL.................

1-1

1-3

NOTES, CAUTIONS, AND WARNINGS ..............................................

1-1

1-4

CHANGES TO TECHNICAL MANUAL...............................................

1-2

1-5

GLOSSARY OF TERMS.........................................................................

1-2

1-6

MEASUREMENT UNITS.......................................................................

1-2

1-7

SAFETY PRECAUTIONS ......................................................................

1-14

1-7.1

Material Hazards................................................................................

1-14

1-7.2

Fire Hazards.......................................................................................

1-14

1-7.3

Compressed Air Hazards ...................................................................

1-15

1-7.4

Heated/Chilled Part Hazards..............................................................

1-15

1-7.5

Electrical Hazards ..............................................................................

1-15

1-7.6

Paints and Finishes Hazards ..............................................................

1-15

1-7.7

Procedural Hazards ............................................................................

1-15

1-7.8

Tooling Hazards .................................................................................

1-16

1-7.9

Environmental Hazards......................................................................

1-16

1-7.10

Gas Turbine Operational Hazards......................................................

1-16

Gas Generator/Gas Turbine General Description, Model Summary, and Heritage.......................................................................................

2-1

2-1

PURPOSE AND SCOPE .........................................................................

2-1

2-2

GENERAL DESCRIPTION AND FEATURES ......................................

2-1

2-2.1

General Description ...........................................................................

2-1

2-2.2

Standard Equipment and Features .....................................................

2-1

2-2.3

Standard Instrumentation ...................................................................

2-2

2-2.4

Standard Supply Requirements..........................................................

2-3

2-2.5

Optional Equipment...........................................................................

2-3

2-3

MODEL SUMMARY ..............................................................................

2-6

2-4

HERITAGE OF THE LM2500+ SAC .....................................................

2-8

2-4.1

Gas Generator Changes .....................................................................

2-8

2-4.2

6-Stage Power Turbine Changes (PK Models) ..................................

2-8

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

i

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page Chapter 3

Chapter 4

Gas Turbine Package...........................................................................................

3-1

3-1

PURPOSE AND SCOPE .........................................................................

3-1

3-2

PACKAGE DESCRIPTION.....................................................................

3-1

Gas Turbine Assembly Description....................................................................

4-1

4-1

PURPOSE AND SCOPE .........................................................................

4-1

4-2

GENERAL DESCRIPTION.....................................................................

4-1

4-2.1

Main Components..............................................................................

4-1

4-2.2

Engine Airflow ..................................................................................

4-2

4-3

COMPRESSOR FRONT FRAME...........................................................

4-2

4-4

HIGH PRESSURE COMPRESSOR........................................................

4-2

4-4.1

General Description ...........................................................................

4-2

4-4.2

High Pressure Compressor Rotor ......................................................

4-14

4-4.3

High Pressure Compressor Stator ......................................................

4-17

4-4.4

Compressor Rear Frame ....................................................................

4-18

COMBUSTION SECTION......................................................................

4-21

4-5.1

General Description ...........................................................................

4-21

4-5.2

Cowl Assembly..................................................................................

4-21

4-5.3

Dome..................................................................................................

4-21

4-5.4

Combustor Liners ..............................................................................

4-21

4-5.5

Igniter/Flame Sensor..........................................................................

4-21

HIGH PRESSURE TURBINE.................................................................

4-23

4-6.1

General Description ...........................................................................

4-23

4-6.2

Stage 1 HPT Nozzle Assembly ..........................................................

4-23

4-6.3

High Pressure Turbine Rotor .............................................................

4-23

4-6.4

Stage 2 HPT Nozzle Assembly ..........................................................

4-28

4-6.5

Turbine Mid Frame Assembly ...........................................................

4-32

ACCESSORY DRIVE COMPONENTS .................................................

4-32

4-7.1

General...............................................................................................

4-32

4-7.2

Accessory Drive Train .......................................................................

4-32

4-7.3

Inlet Gearbox .....................................................................................

4-36

4-7.4

Radial Drive Shaft .............................................................................

4-36

4-7.5

Transfer Gearbox ...............................................................................

4-36

4-7.6

Accessory Gearbox ............................................................................

4-38

4-7.7

Air-Oil Separator ...............................................................................

4-38

4-5

4-6

4-7

ii

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LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page 4-7.8

Lube and Scavenge Pump..................................................................

4-38

POWER TURBINE..................................................................................

4-38

4-8.1

General...............................................................................................

4-38

4-8.2

Power Turbine Rotor..........................................................................

4-41

4-8.2.1 Blades and Seals.......................................................................... 4-8.3 Power Turbine Stator .........................................................................

4-41 4-41

4-8

4-8.3.1

Stage 1 Nozzle.............................................................................

4-41

4-8.3.2 Shrouds and Seals........................................................................ 4-8.4 Turbine Rear Frame ...........................................................................

4-41 4-41

4-8.5

Flexible Coupling Adapter.................................................................

4-44

BEARINGS ..............................................................................................

4-44

4-9.1

General...............................................................................................

4-44

4-9.2

Gas Generator ....................................................................................

4-44

4-9.3

Power Turbine (6-Stage)....................................................................

4-44

4-9.4

Mounting............................................................................................

4-44

SEALS......................................................................................................

4-44

4-9

4-10

Chapter 5

4-10.1

Oil Seals.............................................................................................

4-44

4-10.2

Air Seals.............................................................................................

4-46

LM2500+ SAC System Descriptions..................................................................

5-1

5-1

PURPOSE AND SCOPE .........................................................................

5-1

5-2

VARIABLE-GEOMETRY CONTROL SYSTEM ..................................

5-1

Variable Stator Vane System..............................................................

5-1

FUEL SYSTEM .......................................................................................

5-3

General...............................................................................................

5-3

5-3.1.1

Natural Gas..................................................................................

5-3

5-3.1.2

Fuel Manifold..............................................................................

5-4

5-3.1.3

Fuel Nozzles................................................................................

5-4

5-3.1.4 Fuel Control System.................................................................... 5-4 STARTING SYSTEM ..............................................................................

5-4 5-4

5-2.1 5-3 5-3.1

5-4.1

GE Starter Usage ...............................................................................

5-17

5-4.2

Starter Duty Cycles ............................................................................

5-17

5-4.2.1

Air and Gas Starters ....................................................................

5-17

5-4.2.2

Hydraulic Starter .........................................................................

5-17

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iii

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page 5-5

LUBE SYSTEM.......................................................................................

5-18

5-5.1

General Description ...........................................................................

5-18

5-5.2

System Flows, Pressures, and Temperatures .....................................

5-18

5-5.3

Oil Specification ................................................................................

5-18

5-5.4

Lube Subsystems ...............................................................................

5-18

5-5.4.1

Lube Supply Circuit ....................................................................

5-18

5-5.4.2

Scavenge Oil Circuit ...................................................................

5-19

5-5.4.3

Engine Drains..............................................................................

5-19

5-5.4.4 Sump Vent Circuit ....................................................................... 5-5.5 Sump Pressurization ..........................................................................

5-19 5-27

5-5.6

Oil Consumption................................................................................

5-27

SENSORS AND INDICATING SYSTEMs ............................................

5-29

5-6.1

Gas Generator Speed (NGG) Sensor .................................................

5-29

5-6.2

Power Turbine Speed (NPT) Sensor (Gas Turbine Only)..................

5-29

5-6.3

Vibration Sensors...............................................................................

5-29

5-6.4

Pressure/ Temperature Sensors ..........................................................

5-29

5-6.4.1

HPC Total Pressure Probe/ Inlet Air Temperature (P2/T2) .......

5-29

5-6.4.2

HPC Discharge Temperature (T3)...............................................

5-29

5-6.4.3

Exhaust Gas Temperature (T5.4) ................................................

5-29

5-6.4.4

Fuel Temperature Sensors (Dual Fuel and Gas/Water Systems).......................................................

5-6

5-6.4.5

5-6.4.6 Additional Pressure Parameters .................................................. 5-6.5 Chip Detectors ...................................................................................

5-32 5-32

5-6.6

Variable-Geometry Position...............................................................

5-32

5-6.7

Flame Sensors ....................................................................................

5-32

ELECTRICAL SYSTEM.........................................................................

5-33

5-7.1

Ignition System ..................................................................................

5-33

5-7.2

Cabling...............................................................................................

5-33

BLEED AIR SYSTEM ............................................................................

5-33

Compressor Discharge Pressure Bleed ..............................................

5-33

5-9

BALANCE PISTON SYSTEM (GT ONLY) ...........................................

5-33

5-10

HIGH PRESSURE RECOUP SYSTEM..................................................

5-33

5-7

5-8 5-8.1

iv

5-29 Lube Supply and Scavenge Temperature .................................... 5-32

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LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page 5-11

AIR SYSTEM TUBING AND FRAME STRUT FUNCTIONS.............

5-11.1 5-12 Chapter 6

5-36

A-, B-, C-, and D-Sump Vents ...........................................................

5-36

ENGINE CONTROL UNIT.....................................................................

5-36

Service and Support Requirements ...................................................................

6-1

6-1

PURPOSE AND SCOPE .........................................................................

6-1

6-2

SHIPPING ................................................................................................

6-1

6-2.1

Engine Shipment................................................................................

6-1

6-2.2

Engine Shipping Container................................................................

6-2

6-2.3

Power Turbine Shipment ...................................................................

6-2

6-2.4

Power Turbine Shipping Container ...................................................

6-2

6-2.5

Enclosure Shipping ............................................................................

6-2

6-2.6

Highway Shipping .............................................................................

6-2

6-2.7

On-Site Transportation.......................................................................

6-5

6-3

STORAGE................................................................................................

6-5

6-4

INSTALLATION/REMOVAL .................................................................

6-5

6-4.1

Installation/Removal Methods...........................................................

6-5

6-4.2

Size/Weight ........................................................................................

6-5

6-4.2.1 Major Component Weights ......................................................... 6-4.3 Engine Mount Attachments ...............................................................

6-7 6-8

6-4.4

6-8

6-5

Flange Interfaces................................................................................ AUXILIARY SYSTEMS .........................................................................

6-11

Inlet System .......................................................................................

6-11

Air Filtration................................................................................

6-11

6-5.1.2 Anti-Icing .................................................................................... 6-5.2 Exhaust System..................................................................................

6-11 6-12

6-5.3

Secondary Cooling Air ......................................................................

6-12

6-6

SUPPORT SERVICES .............................................................................

6-12

6-7

MAINTENANCE.....................................................................................

6-13

6-5.1 6-5.1.1

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v

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page Chapter 7

Installation/Initial Startup and Engine Operation ...........................................

7-1

7-1

PURPOSE AND SCOPE .........................................................................

7-1

7-2

SAFETY...................................................................................................

7-1

Engine Maintenance/ Inspection Precautions ....................................

7-2

INSTALLATION......................................................................................

7-3

7-3.1

Site Information .................................................................................

7-3

7-3.2

Installation Procedure ........................................................................

7-3

7-3.3

Equipment Protection ........................................................................

7-3

7-3.3.1

Inlet Cover...................................................................................

7-3

7-3.3.2

Exhaust Cover .............................................................................

7-3

7-3.3.3 Electrical, Fluid, and System Interface Covers ........................... 7-3.4 Engine Protection...............................................................................

7-3 7-3

7-2.1 7-3

7-3.4.1

Lubricating Oil Requirements.....................................................

7-4

7-3.4.2

Lube Oil Pressure Corrections For Industrial LM2500+ SAC Gas Turbines and Gas Generators ............................. Air................................................................................................

7-4 7-5

7-3.4.3

Gas Fuel.......................................................................................

7-5

7-3.4.3.1 Liquid Fuel .......................................................................... 7-3.4.4 NOx Suppression.........................................................................

7-5 7-5

7-3.4.1.1

7-3.4.5 7-3.4.6

7-18

7-3.5

Adjustment of Power Turbine (PT) Thrust Balance Cavity Pressure Within Preferred Operating Range (6-Stage PT Applications Only) .......................................................................... 7-18 Initial Prestart Inspections ................................................................. 7-18

7-3.6

Initial Operational Checkout..............................................................

7-19

7-3.7

Verification Test .................................................................................

7-21

ENGINE OPERATION............................................................................

7-27

7-4.1

Component Life/Repair Intervals ......................................................

7-27

7-4.2

Prestart Checks ..................................................................................

7-27

7-4.3

Motoring Procedures..........................................................................

7-28

7-4.4

Starting and Operation .......................................................................

7-28

Normal Starting Sequence...........................................................

7-28

7-4.4.2 Hot Starts..................................................................................... 7-4.5 Shutdown ...........................................................................................

7-29 7-30

7-4

7-4.4.1

7-4.5.1 vi

Adjustment of Engine High Pressure Recoup Cavity Pressure Within Preferred Operating Range................................................

Normal Shutdown .......................................................................

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7-30

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page 7-4.5.2

Chapter 8

Emergency Shutdown .................................................................

7-31

7-4.5.3 Post-Shutdown Fire ..................................................................... 7-4.6 Starter Duty Cycle - Air, Natural Gas, or Hydraulic .........................

7-32 7-32

7-4.7

Restart ................................................................................................

7-33

7-4.7.1 Hot Restarts ................................................................................. 7-4.8 Windmilling .......................................................................................

7-33 7-34

7-4.9

7-34

Records and Running Logs................................................................

Abnormal Operation ...........................................................................................

8-1

8-1

PURPOSE AND SCOPE .........................................................................

8-1

8-2

GENERAL DEFINITIONS .....................................................................

8-1

8-3

CONTROL ACTIONS.............................................................................

8-1

8-3.1

Alarms................................................................................................

8-1

8-3.2

Power Cutback...................................................................................

8-1

8-3.3

Shutdowns..........................................................................................

8-1

8-3.3.1

Normal Shutdown .......................................................................

8-2

8-3.3.2

Emergency Shutdown .................................................................

8-2

8-3.3.3

Step Deceleration to Idle/Shutdown............................................

8-2

8-3.3.4

Slow Deceleration to Idle/Shutdown...........................................

8-2

8-3.3.5 Aborted Start/Shutdown .............................................................. 8-4 OPERATOR ACTION .............................................................................

8-3 8-3

8-4.1

Chapter 9

Special Gas Turbine Constraints........................................................

8-4

8-4.1.1

Overtemperature During Starting................................................

8-4

8-4.1.2

Lube Oil Pressure ........................................................................

8-4

8-4.1.3

High Speed Stall..........................................................................

8-4

8-4.1.4

Restart Following High Power Trip ............................................

8-5

8-4.1.5

No Power Turbine Rotation ........................................................

8-5

Troubleshooting ...................................................................................................

9-1

9-1

PURPOSE AND SCOPE .........................................................................

9-1

9-2

ARRANGEMENT AND USE .................................................................

9-1

Engine Troubleshooting.....................................................................

9-1

9-2.1.1

Introduction .................................................................................

9-1

9-2.1.2

Gas Generator Speed Instrumentation Functional Check ........................................................................................... 9-2

9-2.2

Troubleshooting Reference Table................................................

9-2.1

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9-2 vii

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page

Chapter 10

9-2.3

Numbered Troubleshooting Procedures ............................................

9-2

9-2.4

Using This Chapter ............................................................................

9-2

General Maintenance Practices..........................................................................

10-1

10-1

PURPOSE AND SCOPE .........................................................................

10-1

10-2

LEVELS OF MAINTENANCE...............................................................

10-1

10-3

POINTS OF REFERENCE ......................................................................

10-1

10-4

STANDARD MAINTENANCE PRACTICES........................................

10-1

10-4.1

Safety .................................................................................................

10-1

10-4.2

Tools and Tasks..................................................................................

10-2

10-4.3

Torque ................................................................................................

10-2

10-4.3.1

Standard Torque ..........................................................................

10-7

10-4.3.2

Running Torque...........................................................................

10-8

10-4.3.3 Tightening Procedures................................................................. 10-4.4 Loose Fasteners..................................................................................

10-8 10-10

10-4.5

10-10

Tri-Wing/Torx Fasteners....................................................................

10-4.5.1

Installation...................................................................................

10-10

10-4.5.2 Extraction .................................................................................... 10-4.6 Universal Fittings...............................................................................

10-12 10-12

10-4.6.1

Nonpositioning Fittings...............................................................

10-12

10-4.6.2

Positioning Fittings .....................................................................

10-13

10-4.6.3 Bulkhead Fittings ........................................................................ 10-4.7 Gaskets, Preformed Packings, and Expendable Parts........................

10-13 10-15

10-4.8

Tubes..................................................................................................

10-15

10-4.9

Hoses..................................................................................................

10-17

10-4.10

Correction of Leaks ...........................................................................

10-20

10-4.11

Clamps ...............................................................................................

10-20

10-4.12

V-Band (Coupling) Clamps ...............................................................

10-20

10-4.12.1

viii

Preinstallation Checks .................................................................

10-20

10-4.12.2 Installation................................................................................... 10-4.13 Electrical Cables and Connectors ......................................................

10-22 10-23

10-4.14

Electrical Bonding Straps ..................................................................

10-24

10-4.15

Safety Wiring .....................................................................................

10-25

10-4.15.1

Safety Wiring General Practices .................................................

10-25

10-4.15.2

Safety Wire Installation...............................................................

10-28

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LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page 10-4.16

Safety Cable.......................................................................................

10-29

10-4.16.1

Safety Cable General Practices ...................................................

10-29

10-4.16.2

Crimping Tool Verification .........................................................

10-30

10-4.16.3

Safety Cable Installation .............................................................

10-30

10-4.17

Jackscrews .........................................................................................

10-31

10-4.18 10-4.19

Protective Closures and Caps ............................................................ Cleanliness .........................................................................................

10-33 10-33

10-4.20

Unpacking and Repacking .................................................................

10-33

10-4.21

Bearing Handling...............................................................................

10-34

10-4.21.1

Preservation.................................................................................

10-34

10-4.21.2

Heating and Chilling ...................................................................

10-34

10-4.22

Marking of Parts ................................................................................

10-35

10-4.23

Blending.............................................................................................

10-36

10-4.23.1

Blending General Practices .........................................................

10-36

10-4.23.2

Hand Blending.............................................................................

10-36

10-4.23.3

Power Blending ...........................................................................

10-37

10-4.23.4

Component Specific Requirements.............................................

10-37

10-4.24

Swab Etching Procedure....................................................................

10-42

10-4.25

Spot-Fluorescent-Penetrant Inspection ..............................................

10-42

10-4.25.1

Spot-Fluorescent-Penetrant Inspection Equipment/ Materials....................................................................................... 10-4.25.2 Spot-Fluorescent-Penetrant Inspection Procedure ...................... 10-4.26 Miscellaneous Procedures.................................................................. Chapter 11

10-43 10-44 10-45

Preventive Maintenance......................................................................................

11-1

11-1

PURPOSE AND SCOPE .........................................................................

11-1

11-2

GENERAL CHECKS AND INSPECTIONS ..........................................

11-1

11-2.1

Special Inspections ............................................................................

11-1

11-3

MOTORING ............................................................................................

11-3

11-4

IDLE CHECKS ........................................................................................

11-3

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ix

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GEK 105054 Volume I

Table of Contents - (Cont.) Page Chapter 12

Appendix A

Critical Parts Life Management for LM2500+ Industrial Gas Turbines...................................................................... 12-1

INTRODUCTION....................................................................................

12-1 12-1

12-2

DEFINITIONS .........................................................................................

12-2

12-3

AFFECTED PARTS.................................................................................

12-2

12-4

PARAMETERS TO BE TRACKED........................................................

12-2

12-5

CALCULATING ACCUMULATED CYCLES AND RECORDING DATA................................................................................

12-3

Gas and Liquid Fuel, Water, Steam, and Detergent Requirements ................ A-1 A1 Fuel Gases for Combustion in GE AeroDerivative Gas Turbines A-3 A1.1 APPLICABLE DOCUMENTS................................................... A1.2 Fuel Gas Classification................................................................ A1.2.1 Natural Gas, Liquefied Natural Gas (LNG), Medium BTU Natural Gas, and Liquefied Petroleum Gas (LPG) ................. A1.2.1.1 Pipeline Natural Gas ...................................................... A1.2.1.2 Liquefied Natural Gas .................................................... A1.2.1.3 Medium BTU Natural Gas ............................................. A1.2.1.4 Liquefied Petroleum Gases ............................................ A1.2.2 Gasification Fuels ................................................................. A1.2.2.1 Oxygen Blown Gasification........................................... A1.2.2.2 Air Blown Gasification .................................................. A1.2.3 Process Gases........................................................................ A1.2.3.1 Blast Furnace Gases ....................................................... A1.2.3.2 Coke Oven Gases ........................................................... A1.2.3.3 Flare Gases ..................................................................... A1.3 Fuel Properties............................................................................. A1.3.1 Heating Value........................................................................ A1.3.2 Modified Wobbe Index Range.............................................. A1.3.3 Superheat Requirement......................................................... A1.3.4 Gas Constituent Limits ......................................................... A1.3.5 Gas Fuel Supply Pressure ..................................................... A1.4 Contaminants............................................................................... A1.4.1 Particulates............................................................................ A1.4.2 Liquids .................................................................................. A1.4.3 Sulfur .................................................................................... A1.4.3.1 Hot Gas Path Corrosion ................................................. A1.4.3.2 Heat Recovery Steam Generator Corrosion ...................

x

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A-3 A-8 A-8 A-8 A-8 A-8 A-8 A-9 A-9 A-9 A-9 A-10 A-10 A-10 A-11 A-11 A-11 A-12 A-12 A-12 A-12 A-13 A-13 A-13 A-13 A-14

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page A1.4.3.3 Selective Catalytic Reduction Deposition...................... A1.4.3.4 Exhaust Emissions ......................................................... A1.4.3.5 Elemental Sulfur Deposition .......................................... A1.5 Definitions................................................................................... A1.5.1 Dew Point ............................................................................. A1.5.2 Dry Saturated Condition ....................................................... A1.5.3 Gas Hydrates......................................................................... A1.5.4 Gas Hydrate Formation Line ................................................ A1.5.5 Glycol ................................................................................... A1.5.7 Superheat .............................................................................. A1.5.8 Saturation Line...................................................................... A1.5.9 Wet Saturated Condition....................................................... A2

A-14 A-14 A-15 A-15 A-15 A-15 A-15 A-16 A-16 A-16 A-16 A-16

Liquid Fuel Requirements for GE AeroDerivative Gas Turbines A-17

A2.1 FUEL SPECIFICATIONS........................................................... A2.2 PROPERTY REQUIREMENTS................................................. A2.2.1 Composition.......................................................................... A2.2.2 Viscosity ............................................................................... A2.2.3 Wax ....................................................................................... A2.2.4 Additives............................................................................... A2.3 ADDITIONAL REQUIREMENTS ............................................

A-17 A-18 A-18 A-18 A-19 A-19 A-19

A2.3.1 Fuel Temperature Requirements........................................... A2.3.2 Filtration ............................................................................... A2.4 FUEL HANDLING..................................................................... A2.4.1 Additional Requirements for Bio-Diesel Fuel...................... A2.5 FUEL SAMPLING .....................................................................

A-19 A-19 A-19 A-20 A-21

A3

Water Purity Specification for NOx Suppression in GE Aircraft Derivative Gas Turbines in Industrial Applications.................... A-25 A3.1 APPLICABLE DOCUMENTS................................................... A-25 A3.2 REQUIREMENTS ...................................................................... A-25 A3.3 STEAM INJECTION PURITY SPECIFICATION .................... A-26

A4

Compressor Cleaning Water Purity Specification for GE Aircraft Derivative Gas Turbines in Industrial Applications..................... A-26 A4.1 APPLICABLE DOCUMENTS................................................... A-27 A4.2 SAMPLING REQUIREMENTS................................................. A-28 Change 1

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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GEK 105054 Volume I

Table of Contents - (Cont.) Page A4.3 A4.4 A5

CHEMICAL REQUIREMENTS ................................................ A-28 FILTRATION REQUIREMENTS .............................................. A-28 Liquid Detergent for Compressor Cleaning for GE Aircraft Derivative Gas Turbines in Industrial Applications..................... A-29

A5.1 APPLICABLE DOCUMENTS................................................... A5.2 DETERGENT PROPERTIES ..................................................... A5.2.1 Composition.......................................................................... A5.2.2 Biodegradability ................................................................... A5.2.3 Toxicity ................................................................................. A5.2.4 Health and Safety Information.............................................. A5.2.5 Solids .................................................................................... A5.2.6 Physical and Chemical Properties ........................................ A5.3 TEST REQUIREMENTS ........................................................... A5.3.1 Liquid Detergent ................................................................... A5.3.1.1 Residue or Ash Content ................................................. A5.3.1.2 Low-Temperature Stability ............................................ A5.3.1.3 Cold Weather Solution Compatibility ............................ A5.3.1.4 Hard Water Compatibility .............................................. A5.3.1.5 Acid and Alkali Acceptance........................................... A5.3.1.6 Salt Water Tolerance ...................................................... A5.3.1.7 Viscosity......................................................................... A5.3.1.8 Acidity and Alkalinity (pH) ........................................... A5.3.2 Cleaning Solution ................................................................. A5.3.2.1 Corrosive Elements ........................................................ A5.3.2.2 pH................................................................................... A5.4 TEST METHODS ....................................................................... A5.4.1 Residue or Ash Content ........................................................ A5.4.2 Hard Water Compatibility .............................................. A5.4.2.1 Preparation of Synthetic Hard Water ............................. A5.4.2.2 Hard Water Test.............................................................. A5.4.3 Acid and Alkali Acceptance ................................................. A5.4.4 Salt Water Tolerance ............................................................. A5.4.5 Elemental Content ................................................................ A5.5 COMPATIBILITY....................................................................... A5.5.1 Engine Materials................................................................... A5.5.2 Titanium Stress Corrosion .................................................... A5.6 COLD WEATHER USAGE........................................................ xii

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

A-29 A-29 A-29 A-29 A-29 A-29 A-29 A-29 A-30 A-30 A-30 A-30 A-30 A-30 A-30 A-30 A-30 A-30 A-31 A-31 A-31 A-31 A-31 A-31 A-31 A-31 A-32 A-32 A-32 A-32 A-32 A-32 A-32

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents - (Cont.) Page A6

Specification for Lubricating Oil for GE Aircraft Derivative Gas Turbines.............................................................................. A-35

A6.1 A6.2 A6.2.1 A6.2.2 A6.3 A6.3.1 A6.4 A6.4.1 A6.4.2 A6.4.3 A6.4.4

OIL SPECIFICATIONS.............................................................. APPLICABLE DOCUMENTS................................................... U.S. DoD Specifications....................................................... American Society of Testing and Materials.......................... REQUIREMENTS ...................................................................... Material Compatibility.......................................................... QUALIFICATION ...................................................................... Performance Tests................................................................. Service Evaluation Tests....................................................... Qualification Report ............................................................. Approved Lubricating Oils ...................................................

A-35 A-35 A-35 A-35 A-35 A-36 A-36 A-36 A-36 A-36 A-37

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LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Illustrations Figure 1-1 4-1 4-2 4-3 4-3 4-4 4-5 4-5 4-6 4-7 4-8 4-9 4-10 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-19 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 xiv

Page Publication Change Request ........................................................................................ LM2500+ SAC Gas Turbine Cross Section................................................................. LM2500+ SAC Gas Generator Cross Section ............................................................. Gas Generator Major Components (Sheet 1 of 2)........................................................ Gas Generator Major Components (Sheet 2 of 2)........................................................ LM2500+ SAC Power Turbine Cross Section............................................................. Gas Generator Air Flow (Sheet 1 of 2) ........................................................................ Gas Generator Air Flow (Sheet 2 of 2) ........................................................................ Compressor Front Frame Strut Positions ..................................................................... Compressor Front Frame Assembly ............................................................................ Compressor Rotor Assembly ....................................................................................... Compressor Stator Assembly....................................................................................... Compressor Rear Frame Assembly (Sheet 1 of 2)....................................................... Compressor Rear Frame Assembly (Sheet 2 of 2)....................................................... Combustor Assembly Cross Section............................................................................ Stage 1 HPT Nozzle Assembly .................................................................................... Stage 1 HPT Nozzle Cooling ....................................................................................... HPT Rotor Assembly ................................................................................................... HPT Rotor Assembly Cross Section ............................................................................ HPT Rotor Air Flow..................................................................................................... HPT Rotor Blade Cooling ............................................................................................ Stage 2 HPT Nozzle Cooling ....................................................................................... Stage 2 HPT Nozzle Cooling ....................................................................................... Turbine Mid Frame ...................................................................................................... Accessory Drive Train Components ............................................................................ Accessory Gearbox ...................................................................................................... Inlet Gearbox................................................................................................................ Accessory Gearbox (Gas Turbine Configuration) ....................................................... Air-Oil Separator.......................................................................................................... Lube and Scavenge Pump ............................................................................................ Turbine Rear Frame ..................................................................................................... Turbine Rear Frame Cross Section .............................................................................. Gas Turbine Bearings................................................................................................... Labryinth Oil Seal........................................................................................................ Carbon Oil Seal............................................................................................................ Change 1

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1-3 4-3 4-5 4-7 4-8 4-9 4-11 4-12 4-13 4-15 4-16 4-17 4-19 4-20 4-22 4-24 4-25 4-26 4-27 4-28 4-29 4-31 4-31 4-33 4-34 4-35 4-36 4-37 4-39 4-40 4-42 4-43 4-45 4-45 4-46

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Illustrations - (Cont.) Figure 4-32 4-33 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-15 5-15 5-15 5-15 5-16 5-17 5-18 5-19 5-20 5-21 6-1 6-2 6-3 6-3 6-4 6-4 6-5

Page Labryinth/Honeycomb Air Seal ................................................................................... Fishmouth Air Seal ...................................................................................................... VG System ................................................................................................................... Liquid Fuel System Schematic .................................................................................... Liquid Fuel System with Water Injection for NOx Suppression and Steam Injection into CDP Ports for Power Enhancement System Schematic ............................................ Liquid Fuel with Water Injection for NOx Suppression System Schematic................ Natural Gas System Schematic .................................................................................... Natural Gas with Water Injection for NOx Suppression System Schematic ............... Natural Gas with Steam Injection for NOx Suppression System Schematic............... Dual Fuel System Schematic ....................................................................................... Dual Fuel with Steam Injection for NOx Suppression System Schematic .................. Dual Fuel with Water Injection for NOx Suppression System Schematic................... Liquid Fuel Manifold Configuration............................................................................ Natural Gas with Steam Injection for NOx Suppression Fuel Manifold Configuration Dual Fuel Manifold Configuration .............................................................................. Accessory Gearbox Assembly ..................................................................................... LM2500+ SAC Lube System Schematic (Sheet 1 of 5) .............................................. LM2500+ SAC Lube System Schematic (Sheet 2 of 5) .............................................. LM2500+ SAC Lube System Schematic (Sheet 3 of 5) .............................................. LM2500+ SAC Lube System Schematic (Sheet 4 of 5) .............................................. LM2500+ SAC Lube System Schematic (Sheet 5 of 5) .............................................. LM2500+ SAC Engine Sumps and Main Bearing Locations...................................... Sump Function Diagram (Typical) .............................................................................. Speed Pickups. ............................................................................................................. Thermocouple Schematic............................................................................................. Gas Generator Pneumatic Piping - Left Side View...................................................... Gas Generator Pneumatic Piping - Right Side View ................................................... Engine Shipping Container .......................................................................................... Power Turbine Shipping Container (Typical) .............................................................. Maintenance Dolly (Sheet 1 of 2) ................................................................................ Maintenance Dolly (Sheet 2 of 2) ................................................................................ Engine Mount Diagram (Sheet 1 of 2)......................................................................... Engine Mount Diagram (Sheet 2 of 2)......................................................................... Temperature Limits ......................................................................................................

4-47 4-47 5-2 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-20 5-21 5-23 5-25 5-26 5-28 5-28 5-30 5-31 5-34 5-35 6-3 6-4 6-6 6-7 6-9 6-10 6-12

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xv

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Illustrations - (Cont.) Figure

Page

7-1

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil .................................................... 7-7

7-2

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil................................................................................................... 7-9

7-3

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator ................................................................................................. Using MIL-L-23699 Oil

7-4

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator ................................................................................................... 7-13 Using MIL-L-7808 Oil

7-5

LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 1 of 4)........................................................................................................... 7-14 LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas 7-15 Generator Speed Using MIL-L-7808 Oil (Sheet 2 of ................................................. 4)

7-5 7-5

7-11

LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 3 of 4)................................................................................................................. 7-16 LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 4 of ................................................ 4) 7-17

7-5 7-6

Transient Temperature Limits (Typical) ...................................................................... 7-26

9-1

Electrical System Schematic Interface E21A and E21B (Sheet 1 of 8)....................... 9-49

9-1

Electrical System Schematic Interface E7, E12, E14, and E15 (Sheet 2 of 8) ............ 9-50

9-1

Electrical System Schematic Interface E30A and E30B (Sheet 3 of 8)....................... 9-51

9-1

Electrical System Schematic Interface E3C, E4C, E5C, E6C, E11C, and E18C (Sheet 4 of 8)................................................................................................................ 9-52

9-1

Electrical System Schematic Interface E41, E42, E43, E44, and E45 (Sheet 5 of 8)................................................................................................................ Electrical System Schematic Interface E40 (Sheet 6 of 8) .......................................... Electrical System Schematic Interface E1 and E13 (Sheet 8 of 8) .............................. Fuel Nozzle/T48 Probes Relationship.......................................................................... Tightening Sequence for Threaded fasteners ............................................................... Torque Wrench Correction Factor Determination ....................................................... Tri-Wing/Torx Fastener Drive...................................................................................... Nonpositioning Fittings................................................................................................ Positioning Fittings ...................................................................................................... Bulkhead Fittings ......................................................................................................... Flexible Coupling Assembly........................................................................................ Rigid Tube.................................................................................................................... Installation of Hose Assemblies...................................................................................

9-1 9-1 9-1A 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 xvi

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9-53 9-54 9-55 9-56 10-9 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Illustrations - (Cont.) Figure 10-10 10-11 10-12 10-13 10-14 10-15 10-15 10-16 10-17 10-18 10-19 12-11

Page Factory Preformed Hoses............................................................................................. Routing and Clamping Techniques .............................................................................. Installation of Cushion Clamps.................................................................................... V-Band Clamps and Safety-Wiring Techniques .......................................................... Electrical Connectors (Typical) ................................................................................... Safety-Wiring Practices (Sheet 1 of 2)......................................................................... Safety-Wiring Practices (Sheet 2 of 2)......................................................................... Safety Cable Flex Limits.............................................................................................. Airfoil Leading Edge Blending.................................................................................... Airfoil Defect Measurement ........................................................................................ Blending and High Metal Removal ............................................................................. Critical Parts Tracking System Data Sheet Example...................................................

10-19 10-21 10-21 10-23 10-24 10-26 10-27 10-32 10-39 10-40 10-41 12-5

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xvii

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Tables Table

Page

1-1 1-2 1-2 1-4 1-5 2-1 2-2 2-3 5-1

Abbreviations ............................................................................................................... Metric and SI Unit Conversion Factors ....................................................................... Metric and SI Unit Conversion Factors ....................................................................... Temperature Conversion Chart .................................................................................... Conversion Table - Fractions to Decimals ................................................................... Standard Instrumentation ............................................................................................. Supply Connections ..................................................................................................... LM2500+ SAC Configurations.................................................................................... Gas Turbine Lube/Scavenge System ...........................................................................

1-4 1-8 1-8 1-12 1-13 2-3 2-4 2-6 5-27

7-1

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil ...................................................

7-6

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil..................................................................................................

7-8

7-3

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators Using MIL-L-23699 Oil................................................................................................

7-10

7-4

Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators .................................................................................................... 7-12 Using MIL-L-7808 Oil

7-5

Typical Operating Levels ............................................................................................. 7-22

7-6

Limits and Operating Requirements ............................................................................ 7-24

7-7

Gas Turbine/Gas Generator Steam Limits (Steam Only Models)................................ 7-25

7-8

Gas Turbine/Gas Generator Water Injection Limits for NOx Suppression ................. 7-25

7-9

Protective Function Causes Requiring Resolution Prior to Restart or Motoring....................................................................................................................... 7-32

9-1

LVDT/Torque Motor Resistance Values for TS-18...................................................... 9-44

9-2

Flame Detector Resistance Values ............................................................................... 9-44

9-3

Accelerometer Resistance Values ................................................................................ 9-44

9-4

Temperature Sensor Resistance Values for TS-21 ....................................................... 9-45

9-5

Cable Circuit Resistance Values At Room Temperature (or as specified in Tables) ... 9-47

9-6

T2 Resistance Values ................................................................................................... 9-47

9-7

Lube RTD Resistance Values....................................................................................... 9-47

9-8

Lube System Chip Detector ......................................................................................... 9-47

9-9

Speed Sensor Resistance Values .................................................................................. 9-48

9-10

Maximum Allowable Instrumentation and Accessory Temperatures.......................... 9-48

7-2

xviii

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LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

List of Tables - (Cont.) Table 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 11-1 11-2 12-1 A1-1 A1-2a A1-2b A1-3 A2 A3 A4

Page Torque Wrench Ranges and Requirements .................................................................. Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts....................................... Torque Values for Engine Plugs and Unions ............................................................... Torque Values for Tubing Nuts and Hose Fittings....................................................... Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting Locknuts ............................................................................................. Minimum Running Torque for Self-Locking Nuts ...................................................... Tri-Wing/Torx Drivers and Standard-Thread Fasteners............................................... Hose Minimum-Bend Radii ......................................................................................... Installed Safety Wire Flex Limit.................................................................................. Preventive Maintenance and Servicing Checks ........................................................... Definition of Terms...................................................................................................... Declared Life Limits for the LM2500 Plus Engine ..................................................... Fuel Classification........................................................................................................ Fuel Gas Composition Limits for DLE Configuration ................................................ Fuel Gas Composition Limits for SAC Configuration ................................................ Test Methods for Gaseous Fuels .................................................................................. Liquid Fuel Property Requirements............................................................................. Corrosives Level .......................................................................................................... Water-Wash Antifreeze Mixtures.................................................................................

Change 1

10-3 10-4 10-5 10-6 10-7 10-8 10-10 10-19 10-28 11-3 11-5 12-3 A-4 A-4 A-5 A-6 A-22 A-31 A-33

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GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 1 Introduction 1-1

PURPOSE AND SCOPE OF TECHNICAL MANUAL

Volumes I and II of this manual contain information to be used for the on-site installation, operation, and maintenance of the following LM2500+ Singular Annular Combustor (SAC) engine models:

•

LM2500 PK gas turbine

•

LM2500 GK gas generator

•

LM2500 PV gas turbine

•

LM2500 GV gas generator

1-2

ARRANGEMENT AND USE OF TECHNICAL MANUAL

This manual consists of two volumes, each arranged to provide easy access to all required information. Volume I provides general descriptions of the engine and associated systems, as well as operating and troubleshooting information. The chapters in Volume I are numbered with Arabic numerals. Figures, tables, and pages are each numbered sequentially, starting with the number one (1), preceded by the chapter number and a dash, for each chapter; e.g., Figure 1-1. Paragraphs are identified and layered in the following manner: 1-1 1-1.1 1-1.1.1

Main topic/paragraph First-level subordinate paragraph

Second-level subordinate paragraph 1-1.1.1.1 Third-level subordinate paragraph

Volume II contains the individual work packages for on-site maintenance, including engine changeout. Volume II also contains the recommended tooling and consumable provisioning for on-site maintenance, as well as storage and shipment preparation procedures. Level 1 maintenance covers all work on the exterior of an installed gas generator/gas turbine, including scheduled inspections, compressor cleaning (water-wash), and engine changeout. Level 2 modular maintenance covers removal and reinstallation of one or more major sections of the engine. Each work package in Volume II (or subordinate work package, as required) is numbered and arranged in the following general sequence: 1. 2. 3. 4. 5. 6. 7. 1-3

Introduction Reference Material Support Equipment Consumable Material Expendable Material Component Removal Component Installation NOTES, CAUTIONS, AND WARNINGS

Notes, Cautions, and Warnings will be found throughout this publication. It is important that the significance of each is thoroughly understood by personnel using this technical manual. Their definitions are as follows: NOTE Notes highlight an essential procedure or a condition that requires emphasis.

1-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

GE Aircraft Engines Marine & Industrial Customer Service Mail Drop S-155, 1 Neumann Way Cincinnati, Ohio 45215-6301 USA Attention: Documentation Programs

CAUTIONS REFER TO PROCEDURES OR PRACTICES THAT MAY DAMAGE OR DESTROY EQUIPMENT IF NOT FOLLOWED CORRECTLY. WARNING WARNINGS REFER TO PROCEDURES OR PRACTICES THAT MAY RESULT IN INJURY OR DEATH IF NOT FOLLOWED CORRECTLY. 1-4

CHANGES TO TECHNICAL MANUAL

A manual change is defined as the reissue of selected pages of the manual. A revision is defined as the reissue of the entire manual. Changes are indicated by a vertical bar in the margin, alongside the text change. Changes to illustrations, diagrams, and schematics are indicated in the same manner. Since previous change symbols are deleted when a page is subsequently changed, the symbols show the latest changes only. Manual changes and revisions are mailed to all authorized LM2500+ SAC manual holders at the time the issues are published. When changes are received, insert the latest change pages and dispose of superseded pages. Page changes are designated by the change number of the effective change at the bottom of each affected page. Refer to the list of effective pages for current change page applicability. Illustrations (line art and photographs) represent the equipment configuration at time of inclusion in this technical manual. They will not necessarily be changed to represent all and/or the latest equipment or configuration. They are to be used only as an aid to supplement the text and the parts list. Changes or additions deemed necessary for proper operation, maintenance, and safety improvements should be submitted to:

The sample form shown in Figure 1-1 may be reproduced and used for this purpose. 1-5

GLOSSARY OF TERMS

Table 1-1 lists and defines the abbreviations most commonly used in this manual. 1-6

MEASUREMENT UNITS

The Syste`me International d'Unite¢s (SI) or metric system is being adopted throughout the world. For this reason, SI unit conversion tables are shown in Tables 1-2, 1-3, and 1-4. Fractions and decimal equivalents are shown in Table 1-5. The introduction of torque wrenches calibrated in Newton-meters (N•m) has been commensurate with the adoption of the SI system. These will eventually replace torque wrenches calibrated in kilogram-meters (kg m). A quick method to convert kilogram-meters (kg m) to N•m, is to move the decimal point one place to the right. For example, 3.5 kg m would become 35 N•m. Although this technique is not mathematically precise (3.5 kg m actually equals 34.3 N•m), it is considered adequate for general purposes. To convert kilogram-centimeters (kg cm) to N•m, move the decimal point one place to the left. For example, 50 kg cm would become 5.0 N•m. The SI units shown in this manual are direct mathematical conversions and may be rounded off, in most instances, at the user's discretion. Examples of units that may be rounded off are those used for temperatures, torque values, pressures, etc. Examples of SI units that may not be rounded off are those used for drop checks, rigging adjustments, runouts, etc.

1-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 1-1. Publication Change Request 1-3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1-1. Abbreviations

Abbreviation

Definition

Abbreviation

Definition

abs

Absolute

cm³

Cubic Centimeters

AC

Alternating Current

CRF

Compressor Rear Frame

AGB

Accessory Gearbox

CRFV

Compressor Rear Frame Flange Accelerometer

ALF

Aft Looking Forward

CW

Clockwise

amp

Ampere

DC

Direct Current

Assy

Assembly

Dia

Diameter

b

Bar

Dim

Dimension

b (beta)

Variable Stator Position

DLE

Dry Low Emissions

bhp

Brake Horsepower

-dPS3/dt

Negative Rate of Change of Compressor Discharge Static Pressure

Blisk

Blade/Disc Combination

ECU

Electronic Control Unit

Btu

British Thermal Unit

ELBO

Lean Blow-Out

°C

Degrees Centigrade (Celsius)

EMU

Engine Maintenance Unit

cc

Cubic Centimeter

°F

Degrees Fahrenheit

CCW

Counterclockwise

FIR

Full Indicator Reading

CDP

Compressor Discharge Pressure

FMP

Fuel Manifold Pressure

CFF

Compressor Front Frame

FOD

Foreign Object Damage

CG

Center of Gravity

ft

Foot or Feet

cm

Centimeter

ft²

Square Foot or Feet

cm²

Square Centimeters

FWD

Forward

1-4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 1-1. Abbreviations - (Cont.) Abbreviation

Definition

Abbreviation

Definition

g

Gram

IGHP

Isentropic Gas Horsepower

gal

Gallon

IGKW

Isentropic Gas Kilowatt

GEK

GEAE Publication Identification Number

IGV

Inlet Guide Vane

GG

Gas Generator

in.

Inch

GT

Gas Turbine

in.²

Square Inch

Hg

Mercury

in.³

Cubic Inch

Horiz

Horizontal

IPB

Illustrated Parts Breakdown

hp

Horsepower

J

Joules

HP

High Pressure

kg

Kilogram

HPC

High Pressure Compressor

kcal

Kilocalorie

HPCR

High Pressure Compressor Rotor

kg cm

Kilogram-centimeter

HPCS

High Pressure Compressor Stator

kg m

Kilogram-meter

HPT

High Pressure Turbine

kJ

Kilojoules

HPTR

High Pressure Turbine Rotor

kPa

Kilopascal

hr

Hour

kW

Kilowatt

Hz

Hertz

l

Liter

ID

Inside Diameter

lb

Pound

IGB

Inlet Gearbox

lb/ft²

Pound per Square Foot

1-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1-1. Abbreviations - (Cont.)

Abbreviation

Definition

Abbreviation

Definition

l/min

Liters per Minute

OAT

Outside Air Temperature

l/sec

Liters per Second

OD

Outside Diameter

LVDT

Linear-Variable Differential Transformer

OGV

Outlet Guide Vane

m

Meter

oz

Ounce

m³

Cubic Meter

Pa

Pascals

mA

Milliampere

Pamb

Ambient Pressure

Max

Maximum

PCB

Printed Circuit Board

Min

Minimum

PCR

Publications Change Request

mm

Millimeter

PN

Part Number

MW

Megawatt

ppm

Parts per Million

N

Newton

Prcp

High Pressure Recoup Pressure

N•m

Newton-meter

PS3

High Pressure Compressor Discharge Static Pressure

No.

Number

PT

Power Turbine

NGG

Gas Generator Speed

PT5.4 (also referred to as PT48)

Power Turbine Inlet Total Pressure

NOx

Oxides of Nitrogen

P0

Gas Turbine Inlet Pressure

NPT

Power Turbine Speed

P2

Compressor Inlet Total Pressure

1-6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 1-1. Abbreviations - (Cont.) Abbreviation

Definition

Abbreviation

Definition

qt

Quart

Temp

Temperature

rpm

Revolutions per Minute

TGB

Transfer Gearbox

RTD

Resistance Temperature Detector

theta 2

Ratio of Measured Absolute Gas Turbine Inlet Absolute Temperature to Standard Day Absolute Temperature

SAC

Singular Annular Combustor

TMF

Turbine Mid Frame

sec

Second

TRF

Turbine Rear Frame

SG

Specific Gravity

TRFV

Turbine Rear Frame Flange Accelerometer

shp

Shaft Horsepower

T2

Compressor Inlet Total Temperature

SI

Metric System

T3

Compressor Discharge Temperature

S/O

Shutoff

T5.4 (also referred to as T48)

Power Turbine Inlet Temperature

Standard Atmosphere

atm

UV

Ultra Violet

Surf

Surface

v

Volt

SWP

Subordinate Work Package

vac

Volts, Alternating Current

Tamb

Ambient Temperature

VG

Variable-Geometry

TAN

Total Acid Number

VSV

Variable Stator Vane

TBP

To Be Provided

WP

Work Package

T/C

Thermocouple

1-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1-2. Metric and SI Unit Conversion Factors

To Convert From

To

Multiply By

bhp

kW

0.7457142

Btu

Joules (J)

1054.8

Btu/hr

kJ/hr

1.0548

Btu/hr

kcal/hr

0.2520

Btu/kW-hr

Btu/hp-hr

1.341

Btu/kW-hr

kcal/kW-hr

0.25198

Btu/kW-hr

kJ/kW-hr

1.0548

Btu/lb

kcal/kg

0.5555

cm

in.

0.3937

cm

m

0.01

cm

mm

10

cm/sec

ft/sec

0.03281

Degrees Fahrenheit − 32

Degrees Celsius

0.5555

ft²

m²

0.0929

ft³/hr

l/hr

28.32

ft³/hr

m³/hr

0.02832

ft³/min

l/min

28.32

ft³/min

m³/min

0.02832

ft

cm

30.48

ft

m

0.3048

ft lb (lb ft)

kg m

0.1383

ft lb (lb ft)

N•m

1.356

ft lb (lb ft)

Btu

0.001286

1-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 1-2. Metric and SI Unit Conversion Factors - (Cont.) To Convert From

To

Multiply By

ft lb/min

ft lb/sec

0.016667

ft/min

km/hr

0.018288

ft/sec

cm/sec

30.48

ft/sec

m/sec

0.3048

g

oz

0.03527

g/cm³

lb/in.³

0.03613

gal

l

3.785

gal/min

l/sec

0.06309

in.²

m²

645.16

in.³

cm³

16.387

in.

mm

25.4

in.

m

0.02540

in.

cm

2.540

in. Hg (60°F)

pascal (Pa)

0.3377

in. water (60°F)

pascal (Pa)

248.8

kg

lb

2.2046

kg cm

lb in.

0.867

kg m

lb ft

7.233

kg/m²

lb/ft²

0.2048

km

miles

0.6214

kW

bhp

1.3409961

lb

g

453.59

1-9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1-2. Metric and SI Unit Conversion Factors - (Cont.)

To Convert From

To

Multiply By

lb

kg

0.4536

lb

N

4.4482

lb/ft²

kg/m²

4.8828

lb/gal

kg/l

0.11982

lb in.

kg cm

1.1532

lb in.

N•m

0.1129848

lb/in.²

kg/cm²

0.0703

lb/in.²

Pascals (Pa)

6894.76

lb/in.²

kPa

6.8948

lb/hr

kg/hr

0.4536

m²

ft²

10.76426

m³

in.³

61,023

m

cm

100

m

ft

3.2808

m

in.

3937

microinches

micrometers

0.0254

micrometers

microinches

39.37

mile (statute)

km

1.6093

mm

in.

0.03937

N

lb

0.2248

N•m

lb in.

8.850748

N•m

lb ft

0.73756

oz

g

28.3495

1-10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 1-2. Metric and SI Unit Conversion Factors - (Cont.) To Convert From

To

Multiply By

oz/gal

g/l

7.49

psi

kPa

6.894757

qt

l

0.9463

U.S. horsepower

metric horsepower

1.014

U.S. horsepower

kW

0.7457

Table 1-3. Pressure Conversions Bar (b)

Standard Atmosphere (atm )

Kilograms per square centimeter (kg/cm²)

Pounds per square inch (lb/in.²)

Pascals(Pa)

1.0

0.987

1.020

14.504

100,000

1.013

1.0

1.033

14.696

101,325

0.981

0.968

1.0

14.22

98,067

0.0689

0.068

0.0703

1.0

6,895

1-11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1-4. Temperature Conversion Chart

To convert indicated temperature between Fahrenheit and Celsius, find indicated temperature (either Celsius or Fahrenheit) in middle column and read Fahrenheit equivalent in the right column or the Celsius equivalent in the left column. For example, a temperature of 32°F, when selected from the center column, shows a corresponding temperature of 0°C in the left column. A temperature of 0°C, when selected from the center column, shows a corresponding temperature of 32°F in the right column. Temperature Conversion Formulas Temperature (°C) = (Temperature °F - 32) ÷ 1.8 Temperature (°F) = (1.8 x Temperature °C) + 32 -60 to 60 61 to 350 360 to 1050 1060 to 1750 1760 to 2450 2460 to 3000 °C °F °C °F °C °F °C °F °C °F °C °F -51 -60 -76 16.1 61 141.8 182 360 680 571 1060 1940 960 1760 3200 1349 2460 4460 -46 -50 -58 16.7 62 143.6 188 370 698 577 1070 1958 966 1770 3218 1354 2470 4478 -40 -40 -40 17.2 83 145.4 193 380 716 582 1080 1976 971 1780 3236 1360 2480 4496 -34 -30 -22 17.8 64 147.2 199 390 734 588 1090 1994 977 1790 3254 1366 2490 4514 -29 -20 -4 18.3 65 149.0 204 400 752 593 1100 2012 982 1800 3272 1371 2500 4532 -23 -10 14 18.9 66 150.8 210 410 770 599 1110 2030 988 1810 3290 1377 2510 4550 -17.8 0 32 19.4 67 152.6 216 420 788 604 1120 2048 993 1820 3308 1382 2520 4568 -17.2 1 33.8 20.0 68 154.4 221 430 806 610 1130 2066 999 1830 3326 1388 2530 4586 -16.7 2 35.6 20.6 69 156.2 227 440 824 616 1140 2084 1004 1840 3344 1393 2540 4604 -16.1 3 37.4 21.1 70 158.0 232 450 842 621 1150 2102 1010 1850 3362 1399 2550 4622 -15.6 4 39.2 21.7 71 159.8 238 460 860 627 1160 2120 1016 1860 3380 1404 2560 4640 -15.0 5 41.0 22.2 72 161.6 243 470 878 632 1170 2138 1021 1870 3398 1410 2570 4658 -14.4 6 42.8 22.8 73 163.4 249 480 896 638 1180 2156 1027 1880 3416 1416 2580 4676 -13.9 7 44.6 23.3 74 165.2 254 490 914 643 1190 2174 1032 1890 3434 1421 2590 4694 -13.3 8 46.4 23.9 75 167.0 260 500 932 649 1200 2192 1038 1900 3452 1427 2600 4712 -12.8 9 48.2 24.4 76 168.8 266 510 950 654 1210 2210 1043 1910 3470 1432 2610 4730 -12.2 10 50.0 25.0 77 170.6 271 520 968 660 1220 2228 1049 1920 3488 1438 2620 4748 -11.7 11 51.8 25.6 78 172.4 277 530 986 666 1230 2246 1054 1930 3506 1443 2630 4766 -11.1 12 53.6 26.1 79 174.2 282 540 1004 671 1240 2264 1060 1940 3524 1449 2640 4784 -10.6 13 55.4 26.7 80 176.0 288 550 1022 677 1250 2282 1066 1950 3542 1454 2650 4802 -10.0 14 57.2 27.2 81 177.8 293 560 1040 682 1260 2300 1071 1960 3560 1460 2660 4820 - 9.4 15 59.0 27.8 82 179.6 299 570 1058 688 1270 2318 1077 1970 3578 1466 2670 4838 - 8.9 16 60.8 28.3 83 181.4 304 580 1076 693 1280 2336 1082 1980 3596 1471 2680 4856 - 8.3 17 62.6 28.9 84 183.2 310 590 1094 699 1290 2354 1088 1990 3614 1477 2690 4874 - 7.8 18 64.4 29.4 85 185.0 316 600 1112 704 1300 2372 1093 2000 3632 1482 2700 4892 - 7.2 19 66.2 30.0 86 186.8 321 610 1130 710 1310 2390 1099 2010 3650 1488 2710 4910 - 6.7 20 68.0 30.6 87 188.6 327 620 1148 716 1320 2408 1104 2020 3668 1493 2720 4928 - 6.1 21 69.8 31.1 88 190.4 332 630 1166 721 1330 2426 1110 2030 3686 1499 2730 4946 - 5.6 22 71.6 31.7 89 192.2 338 640 1184 727 1340 2444 1116 2040 3704 1504 2740 4964 - 5.0 23 73.4 32.2 90 194.0 343 650 1202 732 1350 2462 1121 2050 3722 1510 2750 4982 - 4.4 24 75.2 32.8 91 195.8 349 660 1220 738 1360 2480 1127 2060 3740 1516 2760 5000 - 3.9 25 77.0 33.3 92 197.6 354 670 1238 743 1370 2498 1132 2070 3758 1521 2770 5018 - 3.3 26 78.8 33.9 93 199.4 360 680 1256 749 1380 2516 1138 2080 3776 1527 2780 5036 - 2.8 27 80.6 34.4 94 201.2 366 690 1274 754 1390 2534 1143 2090 3794 1532 2790 5054 - 2.2 28 82.4 35.0 95 203.0 371 700 1292 760 1400 2552 1149 2100 3812 1538 2800 5072 - 1.7 29 84.2 35.6 96 204.8 377 710 1310 766 1410 2570 1154 2110 3830 1543 2810 5090 - 1.1 30 86.0 36.1 97 206.6 382 720 1328 771 1420 2588 1160 2120 3848 1549 2820 5108 - 0.6 31 87.8 36.7 98 208.4 388 730 1346 777 1430 2606 1166 2130 3866 1554 2830 5126 0.0 32 89.6 37.2 99 210.2 393 740 1364 782 1440 2624 1171 2140 3884 1560 2840 5144 0.6 33 91.4 37.8 100 212.0 399 750 1382 788 1450 2642 1177 2150 3902 1566 2850 5162 1.1 34 93.2 43 110 230 404 760 1400 793 1460 2660 1182 2160 3920 1571 2860 5180 1.7 35 95.0 49 120 248 410 770 1418 799 1470 2678 1188 2170 3938 1577 2870 5198 2.2 36 96.8 54 130 266 416 780 1436 804 1480 2696 1193 2180 3956 1582 2880 5216 2.8 37 98.6 60 140 284 421 790 1454 810 1490 2714 1199 2190 3974 1588 2890 5234 3.3 38 100.4 66 150 302 427 800 1472 816 1500 2732 1204 2200 3992 1593 2900 5252 3.9 39 102.2 71 160 320 432 810 1490 821 1510 2750 1210 2210 4010 1599 2910 5270 4.4 40 104.0 77 170 338 438 820 1508 827 1520 2768 1216 2220 4028 1604 2920 5288 5.0 41 105.8 82 180 356 443 830 1526 832 1530 2786 1221 2230 4046 1610 2930 5306 5.6 42 107.6 88 190 374 449 840 1544 838 1540 2804 1227 2240 4064 1616 2940 5324 6.1 43 109.4 93 200 392 454 850 1562 843 1550 2822 1232 2250 4082 1621 2950 5342 6.7 44 111.2 99 210 410 460 860 1580 849 1560 2840 1238 2260 4100 1627 2960 5360 7.2 45 113.0 104 220 428 466 870 1598 854 1570 2858 1243 2270 4118 1632 2970 5378 7.8 46 114.8 110 230 446 471 880 1616 860 1580 2876 1249 2280 4136 1638 2980 5396 8.3 47 116.6 116 240 464 477 890 1634 866 1590 2894 1254 2290 4154 1643 2990 5414 8.9 48 118.4 121 250 482 482 900 1652 871 1600 2912 1260 2300 4172 1649 3000 5432 9.4 49 120.2 127 260 500 488 910 1670 877 1610 2930 1266 2310 4190 10.0 50 122.0 132 270 518 493 920 1688 882 1620 2948 1271 2320 4208 10.6 51 123.8 138 280 536 499 930 1706 888 1630 2966 1277 2330 4226 11.1 52 125.6 143 290 554 504 940 1724 893 1640 2984 1282 2340 4244 11.7 53 127.4 149 300 572 510 950 1742 899 1650 3002 1288 2350 4262 12.2 54 129.2 154 310 590 516 960 1760 904 1660 3020 1293 2360 4280 12.8 55 131.0 160 320 608 521 970 1778 910 1670 3038 1299 2370 4298 13.3 56 132.8 166 330 626 527 980 1796 916 1680 3056 1304 2380 4316 13.9 57 134.6 171 340 644 532 990 1814 921 1690 3074 1310 2390 4334 14.4 58 136.4 177 350 662 538 1000 1832 927 1700 3092 1316 2400 4352 15.0 59 138.2 543 1010 1850 932 1710 3110 1321 2410 4370 15.6 60 140.0 549 1020 1868 938 1720 3128 1327 2420 4388 554 1030 1886 943 1730 3146 1332 2430 4406 560 1040 1904 949 1740 3164 1338 2440 4424 566 1050 1922 954 1750 3182 1343 2450 4442

1-12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 1-5. Conversion Table - Fractions to Decimals Fraction

Decimal

Fraction

Decimal

Fraction

Decimal

1/64

0.0156

11/32

0.3438

11/16

0.6875

1/32

0.0312

23/64

0.3594

45/64

0.7031

3/64

0.0469

3/8

0.3750

23/32

0.7188

1/16

0.0625

25/64

0.3906

47/64

0.7344

5/64

0.0781

13/32

0.4062

3/4

0.7500

3/32

0.0938

27/64

0.4219

49/64

0.7656

7/64

0.1094

7/16

0.4375

25/32

0.7812

1/8

0.1250

29/64

0.4531

51/64

0.7969

9/64

0.1406

15/32

0.4688

13/16

0.8125

5/32

0.1562

31/64

0.4844

53/64

0.8281

11/64

0.1719

1/2

0.5000

27/32

0.8438

3/16

0.1875

33/64

0.5156

55/64

0.8594

13/64

0.2031

17/32

0.5312

7/8

0.8750

7/32

0.2188

35/64

0.5469

57/64

0.8906

15/64

0.2344

9/16

0.5625

29/32

0.9062

1/4

0.2500

37/64

0.5781

59/64

0.9219

17/64

0.2656

19/32

0.5938

15/16

0.9375

9/32

0.2812

39/64

0.6094

61/64

0.9531

19/64

0.2969

5/8

0.6250

31/32

0.9688

5/16

0.3125

41/64

0.6406

63/64

0.9844

21/64

0.3281

21/32

0.6562

1

1.0000

43/64

0.6719

1-13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 1-7

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines REPORT TO A PHYSICIAN. AVOID SPILLING FREON OR SIMILAR SOLVENTS ON THE SKIN. EXTREMELY RAPID EVAPORATION OF THESE SOLVENTS HAS A REFRIGERATING EFFECT AND MAY CAUSE SERIOUS FROSTBITE. DO NOT ALLOW ADHESIVE TO CONTACT THE SKIN. RAPID BONDING OF CERTAIN ADHESIVES WILL CAUSE INSTANT ADHESION TO BODY MEMBERS OR OBJECTS. DO NOT ATTEMPT TO FORCEFULLY SEPARATE BODY MEMBERS IF BONDED TOGETHER. CONSULT THE AREA SUPERVISOR OR A PHYSICIAN FOR PROCEDURES FOR SEPARATION. CAREFULLY REVIEW THE HAZARD INFORMATION ON THE APPROPRIATE MATERIAL SAFETY DATA SHEET AND FOLLOW ALL APPLICABLE PERSONAL PROTECTION REQUIREMENTS.

SAFETY PRECAUTIONS

This technical manual is designed to provide safe procedures and processes for accomplishing the installation, operation, and maintenance tasks required for the LM2500+ SAC. It is therefore very important that all Warnings and Cautions be clearly understood and observed by users of this manual. This section describes general safety precautions that are not related to specific procedures and therefore do not appear elsewhere in this manual. The precautions should be clearly understood and applied wherever appropriate in all phases of installation, operation, and maintenance. 1-7.1

Material Hazards WARNING

•

•

USE ALL CLEANING SOLVENTS, FUELS, OILS, ADHESIVES, EPOXIES, AND CATALYSTS IN A WELL-VENTILATED AREA. AVOID FREQUENT AND PROLONGED INHALATION OF FUMES. CONCENTRATIONS OF FUMES OF MANY CLEANERS, ADHESIVES, AND ESTERS ARE TOXIC AND WILL CAUSE SERIOUS ADVERSE HEALTH EFFECTS AND POSSIBLE DEATH IF INHALED FREQUENTLY. AVOID FREQUENT OR PROLONGED EXPOSURE TO THE SKIN. WEAR PROTECTIVE CLOTHING AND WASH THOROUGHLY WITH SOAP AND WARM WATER AS SOON AS POSSIBLE AFTER EXPOSURE TO SUCH MATERIALS. TAKE SPECIAL PRECAUTIONS TO PREVENT MATERIALS FROM ENTERING THE EYES. IF EXPOSED, RINSE THE EYES IN AN EYE BATH FOUNTAIN IMMEDIATELY AND

1-7.2

Fire Hazards WARNING

KEEP ALL CLEANING SOLVENTS, FUELS, OILS, ESTERS, AND ADHESIVES AWAY FROM OPEN FLAME SPACE HEATERS, EXPOSED ELEMENT ELECTRIC HEATERS, SPARKS, OR FLAME. DO NOT SMOKE WHEN USING FLAMMABLES, IN THE VICINITY OF FLAMMABLES, OR IN AREAS WHERE FLAMMABLES ARE STORED. PROVIDE ADEQUATE VENTILATION TO DISPERSE CONCENTRATIONS OF POTENTIALLY EXPLOSIVE FUMES OR VAPORS. PROVIDE APPROVED CONTAINERS FOR BULK STORAGE OF FLAMMABLE MATERIALS AND APPROVED DISPENSERS IN THE WORKING AREAS. KEEP ALL CONTAINERS TIGHTLY CLOSED WHEN NOT IN USE.

1-14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

1-7.3

Compressed Air Hazards WARNING

AIR PRESSURE USED IN WORK AREAS FOR CLEANING OR DRYING OPERATIONS SHOULD BE REGULATED TO 29 PSI (200 KPA) OR LESS. USE APPROVED SAFETY EQUIPMENT (GOGGLES/FACE SHIELD) TO PREVENT INJURY TO THE EYES. DO NOT DIRECT THE JET OF COMPRESSED AIR AT YOURSELF OR OTHER PERSONNEL, OR SO THAT DEBRIS IS BLOWN ONTO ADJACENT WORK STATIONS. IF ADDITIONAL AIR PRESSURE IS REQUIRED TO DISLODGE FOREIGN MATERIALS FROM PARTS, ENSURE THAT APPROVED SAFETY EQUIPMENT IS WORN AND MOVE TO AN ISOLATED AREA. BE SURE THAT THE AIR PRESSURE IS AT A SAFE OPERATING PRESSURE. 1-7.4

Heated/Chilled Part Hazards WARNING

USE THERMALLY INSULATED GLOVES WHEN HANDLING HEATED OR CHILLED PARTS TO PREVENT BURNING OR FREEZING HANDS. PARTS CHILLED TO SUPERCOLD TEMPERATURES (-40F TO -65°F [-40C TO -53°C]) CAN CAUSE INSTANT FREEZING OF HANDS IF HANDLED WITHOUT PROTECTIVE GLOVES. 1-7.5

Electrical Hazards WARNING

USE EXTREME CARE WHEN WORKING WITH ELECTRICITY. ELECTRICITY CAN CAUSE SHOCK, BURNS, OR DEATH. ELECTRICAL POWER SHALL BE OFF BEFORE

GEK 105054 Volume I

CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. LETHAL OUTPUT VOLTAGES ARE GENERATED BY THE IGNITION EXCITER. DO NOT ENERGIZE THE EXCITER UNLESS THE OUTPUT CONNECTION IS PROPERLY ISOLATED. BE SURE ALL LEADS ARE CONNECTED AND THE PLUG IS INSTALLED AND ALL PERSONNEL ARE CLEARED TO AT LEAST 5 FT (2.0 M) BEFORE ENERGIZING THE EXCITER FOR FIRING THE PLUG. IF THE EXCITER IS REMOVED, FIRE IT ONLY IN THE ISOLATION CHAMBER OF THE TESTER. 1-7.6

Paints and Finishes Hazards WARNING

APPLY PAINTS, FINISHES, AND PRESERVATIVES IN APPROVED SPRAY BOOTHS OR ISOLATED AREAS EQUIPPED WITH AIR CLEANING AND SPRAY-EVACUATION EQUIPMENT. ENSURE THAT ALL LIGHTING AND ELECTRICAL GEAR IS OF THE EXPLOSIONPROOF TYPE. WEAR APPROPRIATE BREATHING FILTERS, EYE PROTECTION, AND SUCH CLOTHING AS IS REQUIRED TO PROTECT THE SKIN. CONSULT THE MATERIAL SAFETY DATA SHEET FOR SPECIFIC PERSONAL PROTECTION REQUIREMENTS. 1-7.7

Procedural Hazards WARNING

OBSERVE ALL SPECIFIED AND LOGICAL SAFETY PRACTICES WHEN ASSEMBLING OR DISASSEMBLING THE GAS TURBINE. WEAR SAFETY GLASSES OR OTHER APPROPRIATE EYE PROTECTION AT ALL TIMES. DO NOT ALLOW SAFETY WIRE OR WIRE CLIPPINGS 1-15

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

TO FLY FROM THE CUTTER WHEN REMOVING OR INSTALLING WIRE. DO NOT USE FINGERS AS GUIDES WHEN INSTALLING PARTS OR TO CHECK ALIGNMENT OF HOLES. USE ONLY CORRECT TOOLS AND FIXTURES AND ALWAYS USE ONLY AS RECOMMENDED. AVOID SHORT CUTS SUCH AS USING FEWER THAN RECOMMENDED ATTACHING BOLTS OR USING SHORTER OR INFERIOR-GRADE BOLTS. HEED ALL WARNINGS IN THE MANUAL TEXT TO AVOID INJURY TO PERSONNEL OR DAMAGE TO GAS TURBINE PARTS. 1-7.8

EXACTLY IN ORDER TO GUARD AGAINST THE POSSIBLY HAZARDOUS RESULTS OF TOOL MISUSE. 1-7.9

WARNING

•

Tooling Hazards WARNING

•

•

IMPROPERLY MAINTAINED TOOLS AND SUPPORT EQUIPMENT CAN BE DANGEROUS TO PERSONNEL AND CAN DAMAGE GAS TURBINE PARTS. USE TOOLING ONLY FOR THE PURPOSE FOR WHICH IT WAS DESIGNED AND AVOID ABUSE. BE CONSTANTLY ALERT FOR DAMAGED EQUIPMENT AND INITIATE APPROPRIATE ACTION FOR APPROVED REPAIR IMMEDIATELY. WHEN A TORQUE MULTIPLIER IS TO BE USED, IT MUST HAVE ADEQUATE CAPACITY TO MEET THE SPECIFIED TORQUE REQUIREMENT OF THE OPERATION. THE TORQUE MULTIPLIER MANUFACTURER'S INSTRUCTIONS AND THE INSTRUCTIONS CONTAINED HEREIN MUST BE FOLLOWED

Environmental Hazards

THE DISPOSAL OF MANY CLEANING SOLVENTS, FUELS, OILS, ADHESIVES, EPOXIES, AND CATALYSTS ARE REGULATED AND, IF MISMANAGED, COULD CAUSE ENVIRONMENTAL DAMAGE. REVIEW THE MATERIAL SAFETY DATA SHEET, OTHER PRODUCT INFORMATION, AND APPLICABLE LOCAL, STATE, AND FEDERAL DISPOSAL REQUIREMENTS FOR PROPER WASTE MANAGEMENT PRACTICES.

1-7.10

Gas Turbine Operational Hazards WARNING

•

THE OUTSIDE SURFACES OF THE ENGINE ARE NOT INSULATED. ADEQUATE PRECAUTIONS SHOULD BE TAKEN TO PREVENT OPERATING PERSONNEL FROM INADVERTENTLY COMING IN CONTACT WITH THESE HOT SURFACES.

•

THE LM2500+ SAC GAS GENERATOR/GAS TURBINE IS A SOURCE OF CONSIDERABLE NOISE. IT IS NECESSARY FOR PERSONNEL WORKING ON THE ENGINE OR IN ITS VICINITY TO WEAR PROPER EAR PROTECTION EQUIPMENT WHEN IT IS OPERATING.

1-16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

•

GEK 105054 Volume I

THE LM2500+ SAC ENGINE IS A HIGH SPEED MACHINE. IN THE REMOTE CASE OF COMPONENT FAILURE, THE CASING WOULD CONTAIN COMPRESSOR BLADE AND TURBINE BLADE FAILURES, BUT MIGHT NOT CONTAIN MAJOR COMPRESSOR OR TURBINE DISK FAILURES. OPERATING PERSONNEL SHOULD NOT BE PERMANENTLY STATIONED IN OR NEAR THE PLANE OF THE ROTATING PARTS.

PERSONNEL ARE INSIDE THE ENCLOSURE, ALL PERSONNEL SHOULD IMMEDIATELY EXIT THE ENCLOSURE TO PREVENT INGESTION OF THE EXTINGUISHING MEDIUM. DISCHARGE OF FINE CHEMICAL OR WATER MISTS DIRECTLY ON GAS GENERATOR CASINGS IS PERMISSIBLE. THE USE OF CHEMICAL FIRE EXTINGUISHING MEDIA WILL REQUIRE THE DISASSEMBLY OF THE ENGINE FOR CLEANING. WARNING

WARNING

•

ROTATING PARTS OF THE STARTER OPERATE AT A VERY HIGH SPEED. PERSONNEL SHOULD NOT BE STATIONED IN THE PLANE OF THE STARTER DURING START CYCLE.

•

LOW PRESSURE, HIGH VELOCITY AIRFLOW CREATED BY THE COMPRESSOR CAN DRAW OBJECTS AND/OR PERSONNEL INTO THE ENGINE. ALTHOUGH USE OF AN INLET SCREEN OR OTHER PROTECTIVE MEASURE IS REQUIRED, PERSONNEL SHOULD NOT STAND IN FRONT OF THE INLET WHILE THE ENGINE IS OPERATING.

•

SUITABLE FIRE PROTECTION EQUIPMENT IS REQUIRED FOR EACH INSTALLATION. CARBON DIOXIDE, HALIDES, FOG, WATER, OR CHEMICAL FIRE EXTINGUISHING SYSTEMS MAY BE USED. IN THE EVENT THAT THE FIRE PROTECTION SYSTEM IS DISCHARGED WHILE

•

EXPLOSIVE MIXTURE SENSING DEVICES SHOULD BE PROVIDED TO SENSE ANY LEAKAGE OF FUEL (INTO THE PACKAGER'S ENCLOSURE). THESE DEVICES SHOULD SHUTDOWN THE GAS TURBINE IF LEAKAGE IS PRESENT. IF THIS OCCURS, EXERCISE CAUTION, DETERMINE AND CORRECT THE CAUSE OF THE LEAKAGE BEFORE CONTINUING OPERATION. THE ENCLOSURE AND SURROUNDING AREA SHOULD ALSO BE PROPERLY VENTILATED TO CLEAR ANY EXPLOSIVE FUMES PRIOR TO RESTARTING.

•

WHEN ENTERING THE GAS TURBINE ENCLOSURE, THE FOLLOWING REQUIREMENTS MUST BE MET:

•

THE GAS TURBINE MUST BE SHUT DOWN.

1-17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

•

MODULE ENTRY DURING ENGINE OPERATION IS PROHIBITED IN GENERAL. IF ENTRY SHOULD BE REQUIRED DURING ENGINE OPERATION, CONTACT GE FIELD SERVICE FOR A REPRESENTATIVE WHO IS TRAINED TO ENTER THE MODULE UNDER SUCH CONDITIONS.

•

THE FIRE EXTINGUISHING SYSTEM MUST BE MADE INACTIVE ACCORDING TO THE PACKAGER’S/ CUSTOMER'S PROCEDURES.

•

SECONDARY AIR TO THE ENCLOSURE MUST BE SHUT OFF, SINCE HIGH SECONDARY AIRFLOW MAY PREVENT OPENING OR CLOSING THE ENCLOSURE DOOR.

•

THE ENCLOSURE DOOR SHOULD BE KEPT OPEN. IF THE GAS TURBINE IS OPERATING, AN OBSERVER SHOULD BE STATIONED AT THE ENCLOSURE DOOR AND CONFINED SPACE ENTRY PROCEDURES MUST BE FOLLOWED.

•

ALLOW GAS TURBINE TO COOL DOWN. AVOID CONTACT WITH HOT PARTS, AND WEAR THERMALLY INSULATED GLOVES AS NECESSARY.

•

WHEN THE GAS TURBINE IS OPERATING, DO NOT REMAIN IN THE VICINITY OF THE PACKAGE DOORS. DO NOT LOOK THROUGH ANY GLASS WINDOWS ASSOCIATED WITH PACKAGE WALLS OR DOORS.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

•

EAR PROTECTION MUST BE WORN IF GAS TURBINE IS OPERATING.

•

DO NOT REMAIN IN THE ENCLOSURE OR IN THE PLANE OF ROTATION OF THE STARTER WHEN STARTING OR MOTORING THE GAS TURBINE.

•

WHEN PERFORMING MAINTENANCE ON ELECTRICAL COMPONENTS, AVOID SHOCKS AND BURNS BY TURNING OFF ELECTRICAL POWER TO THOSE COMPONENTS, EXCEPT WHEN POWER IS REQUIRED TO TAKE VOLTAGE MEASUREMENTS. WARNING

•

LOCK OUT ALL CONTROLS AND SWITCHES, IF POSSIBLE; OTHERWISE, TAG ELECTRICAL SWITCHES, OUT OF SERVICE, TO PREVENT INADVERTENT ACTIVATION. TAG THE ENGINE OPERATING CONTROLS, DO NOT OPERATE, TO PREVENT STARTING DURING A DESIRED SHUTDOWN CONDITION.

1-18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 2 Gas Generator/Gas Turbine General Description, Model Summary, and Heritage •

GG with 17-stage high pressure compressor (HPC), SAC combustor, and 2-stage high pressure turbine (HPT)

•

Six-stage PT (GT only)

•

Inlet duct and centerbody (except spare engine)

•

Accessory gearbox (AGB), consisting of the transfer gearbox (TGB) assembly and the inlet gearbox assembly (IGB)

•

AGB driven lube pump, scavenge pump, hydraulic pump/ variable stator vane (VSV) servovalve, and air/oil separator

The LM2500+ SAC GG and LM2500+ SAC GT is a simple-cycle two shaft machine consisting of a GG and a power turbine (PT). They are direct derivatives of the General Electric (GE) LM2500.

•

Variable-geometry (VG) control system for the VSV system

•

Specified fuel system (nozzles and manifolds)

Application flexibility makes the LM2500+ SAC ideal for a wide variety of mechanical drive, power generation, industrial cogeneration.

•

Ignition system (igniter and exciter)

•

Engine lubrication system (less oil tank, cooler, and filters)

•

Set of instrumentation sensors

•

Forward adapter (for connecting with flex coupling and driven equipment [GT])

2-1

PURPOSE AND SCOPE

This chapter provides a general description of the LM2500+ SAC gas generator (GG)/gas turbine (GT) along with some basic design features, and standard and optional equipment. It also summarizes the various model configurations available, and provides a brief summary of engine heritage and changes from the base LM2500. 2-2

GENERAL DESCRIPTION AND FEATURES

2-2.1

2-2.2 a.

General Description

Standard Equipment and Features

The LM2500+ SAC GG/GT comes fully assembled with the following standard equipment installed and tested at the factory:

2-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

For a complete functional description of the engine and its systems, refer to Chapters 4 and 5 in Volume 1 of this manual.

Individually replaceable stages 1 and 2 HPT stator vanes in pairs.

•

Horizontally split compressor stator and PT casings to facilitate repair and/or detailed inspection.

•

Externally replaceable gearbox bearings and seals.

•

Approximately 40 different ports, specifically located to facilitate borescope inspection. Using the borescope procedure, complete inspection of the GG gas path can be accomplished with the engine installed.

b.

c.

d.

e.

The engine is completely assembled and factory tested. All items listed above are mounted on the engine, except for the ignition system exciter. These components are shipped loose for mounting by the packager/buyer. The GG, PT, or GT is shipped as an assembled unit in a metal reusable container. The remainder of the equipment is shipped in wooden crates. The LM2500+ SAC engine is designed to separate into major modules and structural units to provide maximum flexibility for maintenance programs. The engine can be disassembled into interchangeable modules which can then be individually replaced or repaired. The LM2500+ SAC engine is constructed with a high degree of accessibility. Detail features are specifically aimed at individual component replacements, most of which can be accomplished on an installed engine. Features of the engine include the following:

2-2.3

Standard Instrumentation

The LM2500+ SAC engine is equipped with the sensors shown in Table 2-1. Pressure taps are provided at the following locations for packager-supplied sensors:

•

Lube oil supply line (one location)

•

Lube oil scavenge return line (one location)

•

HPC discharge static pressure (PS3) (two locations on compressor rear frame [CRF])

•

HPC inlet pressure and temperature (P2/ T2) (one location on front frame)

•

PT inlet pressure (PT5.4) (one location on turbine mid frame [TMF]; probe is engine supplied but transducer is purchaser supplied)

•

Accessories/instrumentation externally mounted for ease of replacement.

•

Individually replaceable compressor rotor blades.

•

High pressure recoup pressure (Prcp) (two available locations)

•

Individually replaceable compressor stator vanes.

•

Fuel manifold pressures (depending on selected fuel system)

•

Individually replaceable high pressure turbine rotor (HPTR) blades.

2-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 2-1. Standard Instrumentation Qty/Engine

Parameter/Sensor Description

2

Gas generator rotor speed (NGG) sensors - reluctance-type - located on AGB

2

Power turbine rotor speed (NPT) sensors - reluctance-type - located on turbine rear frame (TRF) (GT only)

1

PT inlet temperature (T5.4) sensing system has eight dual-element chromel/alumel thermocouples - located on TMF

2 (1)

Accelerometers - located on the compressor rear stator case aft flange and turbine rear frame forward flange (GG has forward accelerometer only)

2

Ultraviolet combustor flame sensors (purchaser must supply when required)

6

Resistance temperature detectors (RTDs) - dual-element lube oil supply and scavenge - located in on-engine lube lines

5

Electronic chip detectors - remote-indicating type - located on lube and scavenge pump

1

HPC total inlet pressure and inlet temperature (P2/T2) probe - dualelement RTD and P2 sensing port - located on front frame

2

VSV position sensors - linear variable differential transformer (LVDT) located in both VSV actuators

2

HPC discharge temperature (T3) sensor - dual-element chromel/alumel thermocouple mounted on the compressor rear frame

2 (1)

Fuel temperature sensor (dual fuel systems only) - located on the primary and secondary fuel manifolds or water manifold

•

Second ignition system

See Table 2-2.

•

Inlet screen and inlet seal

2-2.5

•

Ultraviolet flame detectors

•

Air/oil separator piping

•

Mounting kit

2-2.4

Standard Supply Requirements

Optional Equipment

The following optional equipment is available for the LM2500+ SAC GG or GT:

•

Pneumatic or hydraulic starter

•

Exhaust diffuser

2-3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2-2. Supply Connections

Mechanical Interface Connections

Nomenclature

Mates With

F1

Natural Gas Manifold Inlet

Fuel Control Unit

F1A

Gas Manifold Inlet

Fuel Control Unit

F2

Liquid Fuel Manifold Inlet

Fuel Control Unit

F6

Liquid Fuel Manifold Inlet No. 2

Fuel Control Unit

L1

Lube Pump Inlet Port

Line (Part Number [P/N] AN818-24C or MS9197-24) to Lube Pump on GT

L2

Lube Pump Discharge Port

Line (P/N AN818-24C or MS9197-24) from Lube Pump to Oil Supply Filters

L3

Lube Pump Scavenge Oil Discharge Port

Line (P/N AN818-20C or MS9197-20) from GT Scavenge Pump to Oil Scavenge Filter and Cooler

L4

Lube Supply Inlet Port

Line (P/N AN818-16C or MS9197-16) from Oil Supply Filters to GT

A4

Inlet Duct Seal Flange

If Required

A6

Starter Air Inlet Port (Optional)

A7

Starter Air Outlet Port (Optional)

A10

CDP Seal Port Leakage No. 1

If Required

A10A

CDP Seal Port Leakage No. 1 (Alternate)

If Required

A11

CDP Seal Port Leakage No. 2

If Required

A11A

CDP Seal Port Leakage No. 2 (Alternate)

If Required

A12

Air/Oil Separator Discharge Port

Line from Air/Oil Separator to Atmospheric Vent or to Exhaust Duct (Flame Arrestor)

A26

GG Aspirator Air Supply

Tube Flange (P/N 9643M28P24 and V-Band Clamp (P/N 9014M45P24)

D3

Lube Manifold Forward Oil Drain

Line (P/N AN818-6C or MS9197-06)

D5

Lube Manifold Aft Oil Drain

Line (P/N AN818-6C or MS9197-06)

D7

Starter Drain

D8

Lube Pump Maintenance Drain

S1

Water-wash Manifold Inlet Port

Hot Water Line (P/N AN818-16C or MS20819-16C) to Waterwash Manifold on GT Inlet Duct

W1

Fuel Manifold Water Inlet

Line (AN818-12C or MS20819-12C) t.

2-4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 2-2. Supply Connections Mechanical Interface Connections W16 W16A W16B W17 W17A W17B W18 W18A W18B W19 W19A W20 W20A W21 W22 W23 W24 W25 W26 HS1 HS2 HS2A HS4 HS4A

Nomenclature CDP Steam Manifold Inlet (Left) CDP Steam Manifold Inlet (Alternate No. 1 - Left) CDP Steam Manifold Inlet (Alternate No. 2 - Left) CDP Steam Manifold Inlet (Right) CDP Steam Manifold Inlet (Alternate No. 1 - Right) CDP Steam Manifold Inlet (Alternate No. 2 - Right) Steam Manifold Inlet Steam Manifold Inlet No. 1 (Alternate) Steam Manifold Inlet No. 2 (Alternate) Steam Manifold Drain (Right) Steam Manifold Drain (Alternate No. 1 - Right) Steam Manifold Drain (Left) Steam Manifold Drain (Alternate No. 1 - Left) CDP Steam Manifold Drain (Left) CDP Steam Manifold Drain (Right) HP Recoup Steam Drain (Left) HP Recoup Steam Drain (Right) HP Recoup Steam Supply (Right) HP Recoup Steam Supply (Left) Hydraulic Starter Case Drain Hydraulic Starter Inlet Hydraulic Starter Inlet (Alternate) Hydraulic Starter Outlet Hydraulic Starter Outlet (Alternate)

)

Mates With Flange from Steam Supply to CDP Steam Manifold

Flange from Steam Supply to CDP Steam Manifold

Flange from Steam Supply to CDP Steam Manifold

MS20819-12/MS9197-12

MS20819-12/MS9197-12

MS20819-8/MS9197-08 MS20819-8/MS9197-08 MS20819-12/MS9197-12 MS20819-12/MS9197-12 MS20819-12/MS9197-12 MS20819-12/MS9197-12 Line (P/N AN818-12C or MS9197-12) Line (P/N AN818-12C or MS9197-16)

Line (P/N AN818-12C or MS9197-16)

2-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 2-3

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

MODEL SUMMARY

The information in this manual covers various LM2500+ SAC GG and GT model configurations (refer to Table 2-3). A 6-stage or 2-stage PT is available for the GTs. Gas, liquid, and dual fuel capabilities are available. Emissions control with steam or water is available with the LM2500+ SAC:

•

Natural gas/steam injection NOx - 25 ppm

•

Natural gas/water injection NOx - 42 ppm

•

Liquid fuel/water injection NOx - 42 ppm

Injection water or steam also maintains low levels of CO emissions.

Table 2-3. LM2500+ SAC Configurations

Configuration

Fuel System Type

PT Type

NOx Suppression Method

Gas turbine

Gas fuel

6-stage PT

None

7LM2500-PK-MG

Gas turbine

Dual fuel

6-stage PT

None

7LM2500-PK-MD

Gas turbine

Liquid fuel

6-stage PT

None

7LM2500-PK-ML

Gas turbine

Gas fuel

6-stage PT

Steam

7LM2500-PK-MGS

Gas turbine

Dual fuel

6-stage PT

Water

7LM2500-PK-MDW

Gas turbine

Dual fuel

6-stage PT

Steam

7LM2500-PK-MDS

Gas turbine

Liquid fuel

6-stage PT

Steam

7LM2500-PK-MLS

Gas turbine

Liquid fuel

6-stage PT

Water

7LM2500-PK-MLW

Gas turbine

Gas fuel

6-stage PT

Water

7LM2500-PK-MGW

Gas turbine

Liquid fuel

2-stage PT

None

7LM2500-PV-ML

Gas turbine

Gas fuel

2-stage PT

None

7LM2500-PV-MG

Gas turbine

Dual fuel

2-stage PT

None

7LM2500-PV-MD

Gas turbine

Liquid fuel

2-stage PT

Steam

7LM2500-PV-MLS

Gas turbine

Gas fuel

2-stage PT

Water

7LM2500-PV-MGW

Model Number

2-6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 2-3. LM2500+ SAC Configurations - (Cont.)

Configuration

Fuel System Type

PT Type

NOx Suppression Method

Gas turbine

Dual fuel

2-stage PT

Water

7LM2500-PV-MDW

Gas turbine

Liquid fuel

2-stage PT

Water

7LM2500-PV-MLW

Gas turbine

Gas fuel

2-stage PT

Steam

7LM2500-PV-MGS

Gas generator

Gas fuel

None

None

7LM2500-GK-MG

Gas generator

Dual fuel

None

None

7LM2500-GK-MD

Gas generator

Liquid fuel

None

None

7LM2500-GK-ML

Gas generator

Gas fuel

None

Steam

7LM2500-GK-MGS

Gas generator

Dual fuel

None

Water

7LM2500-GK-MDW

Gas generator

Liquid fuel

None

Steam

7LM2500-GK-MLS

Gas generator

Liquid fuel

None

Water

7LM2500-GK-MLW

Gas generator

Gas fuel

None

Water

7LM2500-GK-MGW

Gas generator

Dual fuel

None

None

7LM2500-GV-MD

Gas generator

Gas fuel

None

None

7LM2500-GV-MG

Gas generator

Dual fuel

None

Water

7LM2500-GV-MDW

Model Number

2-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 2-4

HERITAGE OF THE LM2500+ SAC

Building on the LM2500 heritage the LM2500+ SAC has a large percentage of common parts designed for ease of maintenance. It is the differences between the LM2500 and the LM2500+ which allows the LM2500+ SAC to achieve increased power and thermal efficiency. 2-4.1 a.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines e.

Compressor stage 9 air is used in the LM2500+ SAC engine for sump cooling and pressurization. Stage 9 air is also used to cool the struts in the TMF.

f.

The variable stator control for the LM2500+ SAC has been changed from an engine mounted closed loop hydromechanical control and actuation system to an electrohydraulic system, consisting of an on-engine mounted hydraulic pump/VSV servovalve and VSV actuators with integral LVDT, to provide feedback position signals to the off-engine electonic control unit (ECU).

Gas Generator Changes

The addition of one stage of compressor blades, forward of the LM2500’s stage 1 blading, resulting in approximately a 20 percent airflow increase at full power. This new stage, designated as 0, is a wide chord bladed disk or blisk.

2-4.2

6-Stage Power Turbine Changes (PK Models)

a.

The PT is aerodynamically coupled with, and driven by, the exhaust gas from the GG . The increase in power warranted several design changes in the existing PT. The overall flow function is increased 11 percent to account for the higher airflow. The stages 1 and 6 blades are optimized for aerodynamic efficiency. This results in the PT maintaining its current high level of efficiency.

The LM2500’s stage 1 compressor blades have been redesigned to a wide chord design without mid-span dampers.

b.

The PT rotor structure has been strengthened for the higher torque and power of the LM2500+ SAC.

The HPC includes a new IGV assembly and inclusion of more efficient stator airfoils. The compressor pressure ratio increases to 23.1 from 18.8 in the LM2500.

c.

All rotor disks have been increased in mass to provide greater strength and overspeed capability. Disks 1-3 have cooling fins incorporated to lower temperature.

d.

Aft shaft and forward adapter have been redesigned to handle the increased loads for the higher power of the LM2500+ SAC.

b.

Due to the additional compressor stage, the LM2500+ SAC’s length has increased. The front mount locations were moved axially forward 13.83 inches (345.44 mm) compared to the standard LM2500 SAC engine. Two additional forward mounts have been provided on the lower half of the front frame to allow an alternate means of supporting the front end of the engine.

c.

d.

2-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 3 Gas Turbine Package 3-1

PURPOSE AND SCOPE

This chapter provides a brief general description of a typical LM2500+ SAC gas turbine package and its packager-supplied major components. Since individual packages will vary according to customer installation requirements/ applications, detailed information is not provided in this chapter. For more specific information, review the packager’s drawings and manuals. 3-2

PACKAGE DESCRIPTION

The gas turbine package comprises a complete system built around the LM2500+ SAC gas generator/gas turbine. The package provides the structure, interfaces, service connections, and controls necessary to operate the LM2500+ SAC and to utilize its energy and/or shaft output. This package needs only to be installed or erected at the customer's site and connected to the appropriate interfaces and services (fuel, electric, etc.). Typical package components include:

•

Gas turbine base

•

Mounting structure

•

Sound enclosure

•

Inlet and exhaust systems

•

Controls and electrical systems

•

Drains and vents

•

Fuel, water, steam, lube, and hydraulic systems as applicable

•

Instrumentation and condition-monitoring systems

•

Cooling systems

•

Rear drive interfaces

•

Noise and emission suppression systems

•

Interconnecting wiring and piping

•

Fire and safety systems

•

Starter system

•

Water-wash system

•

Anti-icing sytem, if applicable

3-1/(3-2 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 4 Gas Turbine Assembly Description 4-1

PURPOSE AND SCOPE

This chapter describes the LM2500+ singular annular combustor (SAC) gas generator (GG)/ gas turbine (GT) assemblies and their design features. 4-2

GENERAL DESCRIPTION

4-2.1

Main Components

The LM2500+ SAC GT assembly consists of a GG, power turbine, and output coupling shaft (forward) adapter. Figure 4-1 is a cross section of the engine, showing the major assemblies of the LM2500+ SAC GT. Figure 4-2 and Figure 4-3 identify the LM2500+ SAC GG major assemblies and components. Listed below are the principal LM2500+ SAC assemblies covered in this chapter:

•

Compressor front frame (CFF) assembly

•

Seventeen-stage high pressure compressor (HPC)

•

Compressor rear frame (CRF) assembly

•

Combustion section (SAC)

•

High pressure turbine (HPT)

•

Turbine mid frame (TMF)

•

Accessory drive assembly and accessories

•

Bearings

•

Seals

•

Power turbine (PT) (GT only)

The GG (Figure 4-2) is composed of a 17-stage HPC, a singular annular combustor, a 2-stage HPT, an accessory drive system, and controls and accessories. The HPC and the HPT rotors are connected by mating splines. The HP rotor turns clockwise when viewed from aft, looking forward. The inlet duct and centerbody are the engine inlet components mounted to the CFF. The structural frames provide support for the HPC rotor, bearings, compressor stator, HPT rotor, and PT rotor used in the LM2500+ SAC GT. These include the CFF, CRF, and TMF in the GG and the turbine rear frame (TRF) in the PT. The front of the compressor is supported by the No. 3 roller bearing, which is housed in the CFF hub (A-sump). The rear of the compressor stator is supported by the CRF and the rear of the rotor is supported by the No. 4 ball and No. 4 roller bearings, which are housed in the CRF hub (B-sump). The compressor stator consists of two front casing halves and two rear casing halves which house the variable and fixed vanes. The TMF houses the 5R bearing, which supports the aft end of the high pressure turbine rotor (HPTR) and the 6R bearing, which supports the forward end of the PT rotor in the GT version. The PT (Figure 4-4) joins to the GG via a joining kit to produce the gas turbine assembly.

4-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

For GTs with a 2-stage high speed PT, refer to GEK 105052 and GEK 105053 manuals. The PT is composed of 6-stage or 2-stage low pressure turbine rotor, a low pressure turbine stator, and a TRF. It is aerodynamically coupled to the GG and is driven by the GG exhaust gases. The forward coupling shaft adapter is connected to the PT rotor and provides shaft power to the driven load. 4-2.2

Engine Airflow

See Figure 4-5. The GG compressor draws air through the inlet duct, around the centerbody, and through the CFF. The air then travels through the inlet guide vanes (IGV) and passes into the HPC. The amount of airflow in the 17stage HPC is regulated by IGVs and seven stages of variable stator vanes (VSV); their angular position is changed as a function of compressor inlet temperature (T2) and GG speed (NGG). This provides stall-free operation of the compressor throughout the wide range of rotor speeds and inlet temperatures. Compressor discharge air is then directed to the combustor section. Air entering the combustor is mixed with the fuel provided by the fuel nozzles inside 30 vortex-inducing axial swirl cups located in the combustor dome. The fuel/air mixture is ignited by an igniter that is deactivated once combustion becomes self-sustaining. Combustion gases then exit to the HPT. Hot gases from the combustor are directed into the HPT, which drives the HPC. The exhaust gases exit the HPT and enter the PT, which drives the coupling shaft forward adapter.

The forward adapter mates to the packager supplied coupling shaft. 4-3

COMPRESSOR FRONT FRAME

See Figures 4-6 and 4-7. The CFF assembly forms a flow path for compressor inlet air. Struts between the hub and outer case provide lubrication supply and scavenge for the Asump components. The frame also supports the compressor rotor front bearing, inlet duct, centerbody, forward end of the compressor casing, compressor inlet seals, inlet gearbox (IGB), and the A-sump end cover. The frame provides mounting of attachment provisions for the GG front mounts (top and bottom locations), ground handling mounts, P2/T2 probe, and accessory gearbox (AGB) mounts. The frame contains air passages for sump and seal pressurization and ventilation. The lower frame strut houses the radial drive shaft which transfers power from the IGB to the AGB mounted on the bottom of the frame and compressor case. 4-4 4-4.1

HIGH PRESSURE COMPRESSOR General Description

The LM2500+ SAC HPC is a 17-stage, high pressure ratio, axial flow design. Major components include the high pressure compressor rotor (HPCR), high pressure compressor stator (HPCS), and CRF. The number designations for the stages begins with stage 0 and ends with stage 16. The primary purpose of the compressor section is to compress air for combustion; however, some of the air is extracted for engine component cooling and seal pressurization.

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Figure 4-1. LM2500+ SAC Gas Turbine Cross Section

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Figure 4-2. LM2500+ SAC Gas Generator Cross Section

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Figure 4-3. Gas Generator Major Components (Sheet 1 of 2) 4-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-3. Gas Generator Major Components (Sheet 2 of 2) 4-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-4. LM2500+ SAC Power Turbine Cross Section

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Figure 4-5. Gas Generator Air Flow (Sheet 1 of 2) 4-11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-5. Gas Generator Air Flow (Sheet 2 of 2) 4-12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-6. Compressor Front Frame Strut Positions

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High Pressure Compressor Rotor

See Figure 4-8. The HPCR is a spool/disk structure. It is supported at the forward end by the No. 3 roller bearing, which is housed in the CFF (A-sump). The aft end of the rotor is supported by the No. 4 ball and roller bearings, which are housed in the CRF (B-sump). There are six major structural elements and five bolted joints as follows:

•

Stage 0 blisk and forward shaft with integral wide chord, shroudless blades

•

Stage 1 disk

•

Stage 2 disk with air duct forward interface

•

Stages 3-9 spool

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Stages 10-13 spool with integral aft shaft

•

Overhung stages 14-16 spool

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Bolted and interfering rabbets are used in all flange joints for good positioning of parts and rotor stability. A slip fit, single wall air duct that is supported by the aft shaft and the stage 2 disk, routes pressurization air aft through the center of the rotor for pressurization of the B-sump seals. Use of spools reduces the number of joints and makes it possible for several stages of blades to be carried on a single piece of rotor structure. Stages 1 and 2 disks have a series of single blade axial dovetails, while each of stages 3 through 16 have one circumferential dovetail groove in which blades are retained.

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Figure 4-7. Compressor Front Frame Assembly 4-15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-8. Compressor Rotor Assembly 4-16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Close vane-to-rotor spool and blade-to-stator casing clearances are obtained with metal spray rub coating. Thin squealer tips on the blades and vanes contact the sprayed material. Abrasive action on the tips prevents excessive rub while obtaining minimum clearance. The compressor discharge pressure (CDP) seal serves to establish a differential pressure load to help balance the differences between axial loads of the HPCR and HPTR.

GEK 105054 Volume I

4-4.3

High Pressure Compressor Stator

See Figure 4-9. The HPCS consists of two M152 steel forward casing halves and two rear casing halves of Inconel 718, each split horizontally with all four pieces bolted together. They house the compressor variable and fixed vanes, and provide a structural shell between the CFF and the CRF. The HPCS has one stage of IGVs, 15 stages of stator vanes and outlet guide vanes (OGV). The IGVs and stages 0 through 6 are variable, and their angular positions change as a function of T2 and NGG. This variability gives the vane airfoil the optimum angle of attack for efficient operation without compressor stall.

Figure 4-9. Compressor Stator Assembly

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GEK 105054 Volume I The vane positions are controlled by a variable-geometry (VG) control. The variable stator control for the LM2500+ SAC is an electrohydraulic system consisting of an AGB mounted hydraulic pump/ VSV servovalve, and VSV actuators with integral linear-variable differential transformers (LVDT) to provide feedback position signals to the off-engine electronic control. The variable vanes are actuated by a pair of torque shafts. Each of the torque shaft forward ends is positioned by a hydraulic VSV actuator. Linkages connect directly from the torque shaft to the actuating rings of the variable vanes. The IGVs and stages 1 and 2 vanes are shrouded. These shrouds, which are aluminum extrusions, split into forward and aft halves, and are held together with bolts. Stages 1 and 2 vane shrouds mate with rotor seal teeth. One bleed manifold is integral and another bleed manifold is welded to the stator casings. Bleed air is extracted from the outer annulus area between the airfoils of the stage 9 vanes and is used for sump pressurization, cooling, and PT forward seal pressurization. Bleed air, extracted at stage 13 vanes, is used for cooling stage 2 HPT nozzle and PT balance piston cavity pressurization. Borescope ports are provided in the casing at all stages of vanes to permit internal inspection of the compressor. 4-4.4

Compressor Rear Frame

See Figure 4-10 (Sheets 1 and 2). The CRF assembly is made of Inconel 718 and consists of the outer case, the struts, the hub, and the Bsump housing. Its outer case supports the combustor, fuel manifold(s), 30 fuel nozzles, one igniter plug (two igniters are an option) and stage 2 HPT nozzle support.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Bearing axial and radial loads and a portion of stage 1 HPT nozzle load are taken in the hub and transmitted through 10 radial struts to the case. The hub is a casting which provides about half of the radial lengths of the 10 struts. The outer strut ends are castings which are welded to the hub to complete the struts. The hub and strut assembly is welded to the case. The case is a sheet metal and machined ring weldment that serves as the combustor outer case as well as the structural load path between the compressor casing and the TMF. To provide compressor discharge air for customer bleed, an internal manifold within the frame extracts air from the combustion area and routes it through struts 3, 4, 8, and 9. The HPC discharge temperature (T3) is monitored by two T3 sensors mounted on the CRF. Six borescope ports located in the frame permit inspection of the combustor, fuel nozzles, and stage 1 HPT nozzle. Two borescope ports are provided in the aft portion of the case for inspection of the HPT blades and nozzles. The B-sump housing is fabricated from an Inconel 718 casting that is welded to an Inconel support cone with a machine flange that attaches to the CRF. The housing forms the sump cavity and supports the sump seals, No. 4 race, No. 4 bearing, and lube jet. Sump service tubing attachment points are made with standard fittings, which allow the housing to be removed from the frame without breaking permanent connections. To provide for differential thermal growth between sump service tubing and the surrounding structure, the tubes are attached only at the sump and have slip joints where they pass through the outer strut ends.

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Figure 4-10. Compressor Rear Frame Assembly (Sheet 1 of 2) 4-19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-10. Compressor Rear Frame Assembly (Sheet 2 of 2)

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The CRF, in conjunction with the combustor cowl assembly, serves as a diffuser and distributor of compressor discharge air. The diffuser provides uniform low velocity air to the combustor. 4-5 4-5.1

COMBUSTION SECTION General Description

The combustor is of a singular annular design consisting of four major components: cowl (diffuser) assembly, dome, inner liner, and outer liner. See Figure 4-11. The combustor assembly is mounted in the CRF on 10 equally spaced mounting pins in the forward low temperature section of the cowl assembly. These pins provide positive axial and radial location and assure centering of the cowl asembly in the diffuser passage. The mounting hardware is enclosed within the CRF struts so that it will not affect airflow. 4-5.2

Cowl Assembly

The cowl assembly, in conjunction with the CRF, serves as a diffuser and distributor for the compressor discharge air. It furnishes uniform air flow to the combustor throughout a large operating range, providing uniform combustion at the turbine. The cowl assembly consists of a machined ring and inner and outer cowl inlets welded to the inner and outer cowl wall.

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4-5.3

Dome

The dome houses 30 vortex-inducing axial swirl cups (one at each fuel nozzle tip). The swirl cups provide flame stabilization and mixing of the fuel and air. The interior surface of the dome is protected from the high temperature of combustion by a cooling-air film. Accumulation of carbon on the fuel nozzle tips is prevented by venturi-shaped spools attached to the swirler. 4-5.4

Combustor Liners

The combustor liners are a series of overlapping rings joined by resistance-welded and brazed joints. They are protected from the high combustion heat by circumferential filmcooling. Primary combustion and cooling air enters through closely spaced holes in each ring. These holes help to center the flame and admit the balance of the combustion air. Dilution holes are employed on the outer and inner liners for additional mixing to lower the gas temperature at the turbine inlet. Combustion/ turbine nozzle air seals at the aft end of the liners prevent excessive air leakage while providing for thermal growth. 4-5.5

Igniter/Flame Sensor

The ignition system produces the high-energy sparks that ignite the fuel/air mixture in the combustor during starting. The standard ignition system consists of one ignition exciter, one lead, and one igniter plug. Once ignition occurs, combustion becomes self-sustaining and continues without the igniter. Optional flame sensors monitor the combustion flame.

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Figure 4-11. Combustor Assembly Cross Section

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4-6 4-6.1

HIGH PRESSURE TURBINE General Description

The LM2500+ SAC HPT is an air-cooled, 2stage design with high efficiency. The HPT section consists of the rotor and the stages 1 and 2 HPT nozzle assemblies. The HPT nozzles direct the hot gas from the combustor onto the HPTR blades at the optimum angle and velocity. The HPTR extracts energy from the exhaust gas stream to drive the HPCR to which it is mechanically coupled. 4-6.2

Stage 1 HPT Nozzle Assembly

See Figure 4-12. Stage 1 HPT nozzle directs high pressure gases from the combustion section onto stage 1 turbine blades at the optimum angle and velocity. Stage 1 nozzle vanes are air cooled by convection and film cooling. The major components of stage 1 turbine nozzle assembly are nozzle support, nozzle vane assembly, air baffle, pressure balance seal support, and channel cover. The nozzles are coated to improve corrosion and oxidation resistance. They are bolted to stage 1 nozzle support and receive axial support from stage 2 nozzle support. There are 32 nozzle segments in the assembly, each segment consisting of two vanes. The vanes are cast and then welded into pairs (segments) to decrease the number of gas leakage paths.

GEK 105054 Volume I

These welds are partial-penetration welds to allow easy separation of the segments for repair and replacement of individual vanes. Stage 1 nozzle support, in addition to supporting stage 1 nozzle segments, forms the inner flow path wall from the CRF to the nozzle segments, and is bolted to the aft end of the pressure balance seal support. Stage 1 nozzle assembly is air cooled by convection and film cooling with compressor discharge air that flows through each vane. See Figure 4-13. Internally, the vane is divided into two cavities. Air flowing into the forward cavity is discharged through holes in the leading edge and through gill holes on each side close to the leading edge to form a thin film of cool air over the length of the vane. Air flowing into the aft cavity is discharged through additional gill holes and trailing edge slots. 4-6.3

High Pressure Turbine Rotor

See Figure 4-14. The HPTR consists of a conical forward shaft, two disks with air cooled blades and blade retainers, a conical rotor spacer, a catenary-shaped thermal shield, and an aft shaft. The conical forward HPT shaft transmits energy to the HPCR. Torque is transmitted through the spline joint at the forward end of the shaft. Two air seals are attached to the forward end of the shaft. The forward seal prevents CDP from directly entering the B-sump. The aft seal maintains CDP in the plenum formed by the rotor and the combustor. This plenum is a balance chamber that provides a force that maintains the proper thrust load on the No. 4 ball bearing.

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Figure 4-12. Stage 1 HPT Nozzle Assembly The inner rabbet diameter on the forward shaft rear flange provides a positive radial location for the stage 1 blade retainer and a face seal for the rotor internal cooling air. Windage covers are used with bolts that retain the stage 1 blade retainer to the rotor. Windage covers reduce windage temperature rise. The outer rabbet diameter on the flange provides positive location for stage 1 disk and stability for the rotor assembly. The cone-shaped spacer provides additional stability and is rabbeted between the turbine disks. The spacer also transmits torque from the stage 2 disk to the stage 1 disk. The catenary-shaped thermal shield is also rabbeted between the two disks to form the outer portion of the turbine rotor cooling air cavity, and serves as the rotating portion of the interstage gas path seal. The aft shaft is rabbeted to the stage 2 disk.

The HPTR is cooled by a continuous flow of compressor discharge air that passes through holes in forward turbine shaft. See Figures 415 and 4-16. This air cools the inside of the rotor and both disks before passing between the dovetails and out to the blades. The turbine blades are coated both internally and externally to improve corrosion and oxidation resistance. Stages 1 and 2 HPT blades are cooled by compressor discharge air which flows through the dovetail and the blade airfoil (Figure 4-17). Stage 1 blades are cooled by a combination of internal convection, leading edge internal impingement, and external film cooling.

The disk geometry has 90 boltholes and blade slots in the rim. The inner bolt circle has twenty-four 7/16-inch-diameter bolts.

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Figure 4-13. Stage 1 HPT Nozzle Cooling 4-25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-14. HPT Rotor Assembly 4-26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-15. HPT Rotor Assembly Cross Section

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Figure 4-16. HPT Rotor Air Flow 4-6.4

Stage 2 HPT Nozzle Assembly

Stage 2 HPT nozzle directs the high pressure gases exiting from stage 1 turbine blades onto stage 2 blades at the optimum angle and velocity. The major components of stage 2 nozzle assembly are nozzle support, nozzle vane assembly, stages 1 and 2 turbine shrouds, and interstage seal. See Figure 4-18. The nozzle support is a conical section with a flange that is bolted between the aft flange of the CRF aft outer case and forward flange of the TMF. The support mounts the nozzles, cooling air tubes, and the stages 1 and 2 turbine shrouds. The nozzle vanes are cast, coated, and then welded into pairs (segments) to decrease the number of gas leakage paths. These welds are partial-penetration welds to allow easy separation of the segments for repair and replacement of individual vanes.

The nozzle vanes (two per nozzle segment) direct the gas stream onto stage 2 turbine blades. The interstage seal attaches to the nozzle segment. Stage 2 nozzle assembly is air cooled by convection. The nozzle vane center area and leading edge are cooled by air (stage 13) which enters the nozzle through the cooling air tubes. Some of the air is discharged through holes in the trailing edge, while the remainder flows out through the bottom of the vanes and is used for cooling the interstage seals and thermal shields. See Figure 4-19. The turbine shrouds form a portion of the outer aerodynamic flow path through the turbine. They are located radially in line with the turbine blades and form a pressure seal to prevent excessive gas leakage over the blade tips. Stage 1 consists of 48 segments and stage 2 has 11 segments.

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Figure 4-17. HPT Rotor Blade Cooling 4-29 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-18. Stage 2 HPT Nozzle Assembly 4-30 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-19. Stage 2 HPT Nozzle Cooling 4-31 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I The interstage seal assembly is composed of 11 segments supported from the inner band of the stage 2 nozzle. The seal controls the gas leakage between stage 2 nozzle and the turbine rotor. The sealing surface has three teeth for minimum temperature rise across the teeth. The interstage seal consists of casting brazed to a honeycomb surface. The seals are pregrooved to preclude seal rub under emergency shutdown conditions. 4-6.5

Turbine Mid Frame Assembly

See Figure 4-20. The TMF supports the aft end of the HPTR and the forward end of the PT rotor. It is bolted between the rear flange of the CRF aft outer case and the front flange of the PT stator. The frame provides a smooth diffuser flow passage for HPT discharge air into the PT. Piping for bearing lubrication and seal pressurization is located within the frame struts. The frame contains ports for the PT inlet thermocouples (T5.4) and pressure probe (PT5.4). These ports can be used to provide access for borescope inspection of the PT inlet area. The PT stage 1 nozzles assemble to the TMF assembly. The frame hub is a one-piece casting with flanges to support the sump housing, stationary seals, inner liner support, and PT stage 1 nozzle support. The sump housing is bolted to the forward flange of the hub. The sump housing is of double-wall construction.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines The liner assembly consists of an inner and outer liner and airfoil shaped strut fairings. The strut fairings incorporate a slip joint feature to accommodate thermal expansion. This liner assembly guides the gas flow and shields the main structure from high temperature. The liner assembly is supported at the forward end by inner and outer liner supports. Seals at both ends of the inner and outer liners are provided to prevent excessive leakage of cooling air from behind the liner assembly. 4-7

ACCESSORY DRIVE COMPONENTS

4-7.1

General

See Figures 4-21 through 4-24. The accessory drive section consists of an IGB located in the hub of the CFF, a radial drive shaft inside the 6:00 o’clock position strut of the front frame, and a transfer gearbox (TGB) attached to AGB. Both TGB and AGB are bolted underneath the front frame. The pneumatic or hydraulic starter and the lube and scavenge pump are mounted on the aft side of the AGB. The airoil separator and the hydraulic pump/VSV servovalve are mounted on the front of the AGB. Two NGG sensors are located on the AGB. 4-7.2

Accessory Drive Train

Power to drive the accessories is extracted from the compressor rotor and IGB shaft which is spline-connected to the forward shaft. A set of bevel gears in the IGB transfers this power to the radial drive shaft, which transmits the power to another set of bevel gears in the TGB. A short horizontal drive shaft transmits the power to the AGB and via internal gears to the various accessory drive adapters in the AGB.

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Figure 4-20. Turbine Mid Frame 4-33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-21. Accessory Drive Train Components 4-34 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-22. Accessory Gearbox 4-35 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-23. Inlet Gearbox 4-7.3

Inlet Gearbox

See Figure 4-23. IGB assembly consists of a cast aluminum casing, a shaft, a pair of bevel gears, bearings, and oil jets. The casing, which is bolted inside the CFF hub, mounts two duplex ball bearings and a roller bearing. It has internal oil passages and jets to provide lubrication for the gears and bearings. The shaft, which rotates on a horizontal axis, is splined at the aft end to mate with the forward shaft of the HPCR. The forward end of the shaft mounts the upper bevel gear and is supported by a duplex ball bearing. The lower bevel gear, which rotates on a vertical axis, is supported at its upper end by a roller bearing and at its lower end by a duplex ball bearing. The lower end is also splined to mate with the radial drive shaft.

4-7.4

Radial Drive Shaft

The radial drive shaft, a hollow shaft externally splined on each end, mates with the bevel gears in the IGB and TGB. Its function is to transmit power from the IGB through the TGB. The shaft contains a shear section to prevent damage to the accessory drive system. 4-7.5

Transfer Gearbox

The TGB transfers power from the high pressure rotor system via the IGB and radial drive shaft. The TGB contains a set of right angle bevel gears and a horizontal drive shaft which transmits the power to the gear train in the AGB. Each bevel gear is supported by a duplex ball bearing and a roller bearing. An access cover in the bottom of the casing facilitates installation of the radial drive shaft.

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Figure 4-24. Accessory Gearbox (Gas Turbine Configuration)

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GEK 105054 Volume I 4-7.6

Accessory Gearbox

The AGB assembly consists of a two-piece aluminum casing, gears, bearings, seals, oil nozzles, and accessory adapters. The plug-in gear concept is used on all accessory adapters and idler gears in the aft (accessory) section. This permits an entire gear, bearing, seal, and adapter assembly to be removed and replaced without disassembling the gearbox. Each spur gear is supported by a casing-mounted roller bearing on one end and an adapter-mounted ball bearing on the other end. The accessory drive spur gears are internally splined. Internal tubes and oil nozzles provide lubrication of the gears and bearings. Gearbox carbon face seals are retained from the outside of the gearbox and can be replaced without disassembly of the gearbox.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Small holes in the segments of the impeller allow the collected oil to be discharged to the separator outer housing. Vanes on the housing wall are used to collect and direct the oil to the drainport. To prevent oil and oil vapors from escaping past the end of the impeller, the separator has two labyrinth seals, with the cavity between the two seals pressurized with ejector discharge air. 4-7.8

Lube and Scavenge Pump

•

Pneumatic or hydraulic starter that drives the high pressure rotor through the TGB assembly

See Figure 4-26. The lube and scavenge pump is mounted on the aft side of the AGB and is a five element or six element, positive displacement, vane type pump pump. The five element pump is used on a GG or GT with a 2-stage PT. The six element pump is used on a GT with a 6-stage PT. One element is used for the lube supply and four/five elements are used for lube scavenging. Within the pump are inlet screens, one for each element, and a lube supply pressure limiting valve. Each scavenge return line is equipped with electrical/magnetic remote-reading chip detectors. Each chip detector indicates chip collection when resistance across the detector drops.

•

Lube and scavenge pump

4-8

•

Hydraulic pump/VSV servovalve

4-8.1

•

Packager-supplied accessories, and for manual rotation of the high pressure rotor system during borescope inspection

The AGB provides drive provisions for the following:

4-7.7

Air-Oil Separator

See Figure 4-25. The air-oil separator consists of a fabricated sheet metal impeller with a cast aluminum housing. It is mounted on the AGB. To prevent excessive oil loss from venting oil vapor overboard, all sumps and gearboxes are vented to the air-oil separator. The sump vent air is discharged after passing through the separator. Oil is collected on the inside of the impeller as the oil-laden sump vent air passes through the separator.

POWER TURBINE General NOTE

For GTs with a 2-stage high speed PT, refer to GEK 105052 and GEK 105053 manuals. The PT is a 6-stage aeroderivitive, suited for 3000 - 3600 rpm output speeds. The PT assembly consists of a turbine rotor, stator, rear frame, and high-speed coupling shaft.

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Figure 4-25. Air-Oil Separator

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Figure 4-26. Lube and Scavenge Pump 4-40 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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4-8.2

Power Turbine Rotor

See Figure 4-4. The PT rotor is a 6-stage low pressure turbine rotor mounted between the No. 6 roller bearing, housed in the TMF (Csump), and the No. 7 ball and roller bearings, housed in the TRF (D-sump). It consists of six disks, each having two integral spacers, one on each side (except for stages 1 and 6). Stage 1 has a seal at the forward end. Each disk spacer is attached to the adjacent disk spacer by close-fitting bolts. The front shaft is secured between stage 2 seal spacer and stage 3 disk, and the rear shaft between stage 5 disk and stage 6 rotating seal spacer. 4-8.2.1

Blades and Seals

Blades of all six stages contain interlocking tip shrouds for low vibration levels and are retained in the disks by dovetails. Rotating seals, secured between the disks, mate with stationary seals to prevent excessive gas leakage between stages. Blades are coated for corrosion and oxidation protection where applicable. 4-8.3

Power Turbine Stator

The PT stator consists of two casing halves split horizontally, stages 2 through 6 turbine nozzles, and six stages of blade shrouds. Stages 2 to 3 nozzles have welded segments of six vanes each. Vanes are coated for corrosion and oxidation protection where applicable.

GEK 105054 Volume I

4-8.3.1

Stage 1 Nozzle

Stage 1 nozzle is assembled to the TMF assembly. The PT stage 1 turbine nozzle consists of 14 segments of six vanes each. The inner end is attached to the nozzle support, and the outer end is secured to the outer nozzle support ring which is secured between the frame aft flange and the PT stator front flange. 4-8.3.2

Shrouds and Seals

Honeycomb shrouds, mounted in casing channels, mate with the shrouded blade tips to provide close-clearance seals and also to act as a casing heat shield. The stationary interstage seals are attached to the inner ends of the nozzle vanes to maintain low air leakage between stages. Insulation is installed between nozzles/shrouds and casing to protect the casing from the high temperature of the gas stream. A liner installed for stages 1 through 3 isolates the casing from flow path gases. 4-8.4

Turbine Rear Frame

See Figures 4-27 and 4-28. The TRF consists of an outer casing, eight equally spaced radial struts, and a single-piece casting stainless steel hub. It forms the PT exhaust flow path and supports the aft end of the PT stator case. It also provides a mounting flange for the outer cone of the exhaust system and provides attaching points for the GT rear supports. The hub supports a bearing housing for the No. 7 ball and roller bearings. The bearing housing is a one-piece casing of 17-4 PH stainless steel material. The hub and the bearing housings have flanges to which air and oil seals are attached to form the D-sump.

4-41 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-27. Turbine Rear Frame 4-42 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-28. Turbine Rear Frame Cross Section

4-43 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I The struts contain service lines for lubrication supply, and sump scavenging and venting. Struts No. 3 and 7 also provide the penetration path and the mounting flanges for two reluctance-type PT speed transducers. The latest configuration uses a single dual-output PT speed transducer mounted in the No. 3 strut. 4-8.5

Flexible Coupling Adapter

The PT rotor is splined to a bolted flange adapter. The purchaser’s flexible coupling mates with this adapter. 4-9 4-9.1

BEARINGS General

The GT with 6-stage power turbine assembly consists of two separate rotating systems: the GG and the PT. Seven bearings are used: No. 3R (A-sump), 4R and 4B (B-sump), 5R and 6R, (C-sump), and 7B and 7R (D-sump). See Figure 4-29. The GG and GT with 2-stage PT contain only the first 4 bearings (3R, 4R, 4B, and 5R) 4-9.2 Gas Generator Support for the gas generator rotors consists of a four-bearing system: the No. 3R and 4R bearings are roller bearings mounted on the forward and aft compressor shafts respectively. Bearing No. 4B is a ball bearing and is used to carry the thrust load of the gas generator rotor. The No. 5R bearing is a roller bearing supporting the rear shaft of the gas generator turbine rotor. 4-9.3

Power Turbine (6-Stage)

The PT rotor support consists of three bearings: the No. 6R, 7B, and 7R bearings. The No. 6R and 7R bearings are roller bearings mounted on the forward and aft rotor shafts respectively. The No. 7B bearing is a ball bearing mounted on the rear shaft, just forward of the No. 7R bearing. It carries the thrust load of the PT rotor.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

The rolling member of 6R bearing is mounted in the TMF.

•

The 3R, 4R, 4B, 5R, and 7B are matched bearings and inner races.

4-9.4

Mounting

All bearing outer races, except No. 4B, 5R, and 7R, are flanged. The No. 4B bearing is retained by a spanner nut across its outer face. The No. 5R and 7R bearings are retained by a tabbed ring which engages slots in the outer race. Bearings No. 3R and 5R, under some conditions, can be lightly loaded. To prevent skidding of the rollers under these conditions, the outer race is very slightly elliptical to keep the rollers turning. 4-10 4-10.1

SEALS Oil Seals

See Figures 4-30 and 4-31. The oil seals are of two types: labyrinth seals used in the sump areas, and carbon seals used in the AGB. The labyrinth oil seal combines a rotating seal having oil slingers and a serrated surface with a stationary seal having a smooth rub surface. The oil slingers throw oil into the windback threads which direct the oil back to the sump area. The serrations cut grooves into the smooth surface of the stationary seal to maintain close clearances throughout a large temperature range. This seal allows a small amount of seal pressurization air to leak into the sump, thereby preventing oil leakage. The carbon seal consists of a stationary springloaded carbon sealing ring and a rotating highly polished steel mating ring. It prevents oil in the gearbox from leaking past the drive shafts of the starter, VSV control, and auxiliary drive/fuel pump pads.

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Figure 4-29. Gas Turbine Bearings

Figure 4-30. Labryinth Oil Seal 4-45 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 4-31. Carbon Oil Seal 4-10.2

Air Seals

See Figures 4-32 and 4-33. The GT air seals are of two types: labyrinth/ honeycomb used throughout the gas turbine and fishmouth seal used in the stage 1 nozzle assembly and in the TMF. The labyrinth/ honeycomb seal combines a rotating seal, having knife-like teeth, with a stationary seal, having a honeycomb surface. The teeth cut into the honeycomb to maintain close clearances over a large temperature range.

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Figure 4-32. Labryinth/Honeycomb Air Seal

Figure 4-33. Fishmouth Air Seal

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CHAPTER 5 LM2500+ SAC System Descriptions 5-1

PURPOSE AND SCOPE

This chapter provides physical and functional descriptions of the various systems that are part of the LM2500+ SAC gas turbine/gas generator. Systems described in this chapter include:

5-2

VARIABLE-GEOMETRY CONTROL SYSTEM

The VG control system includes the variable stator vane (VSV) control system. The VG control system consists of the VG hydraulic pump and an electrohydraulic VSV servovalve assembly. The hydraulic pump/ VSV servovalve houses torque motor-positioned hydraulic servos for porting fluid at regulated pressures, and two VSV actuators with integral linear-variable differential transformers (LVDT) to provide feedback position signals to the off-engine ECU. The VG hydraulic pump is a fixed-displacement design which supplies pressurized lube oil to the VSV servovalve assembly for delivery to the actuators.

•

Variable-geometry (VG) control system

•

Fuel system

•

Starting system

•

Lube system

•

Sensors and indicating systems

•

Electrical system

•

Bleed air system

•

Balance piston system for power turbine

Positioning of the inlet guide vanes (IGV) and VSV is scheduled by packager-supplied control system electrical inputs to servovalves.

•

High pressure (HP) recoup system

5-2.1

•

Air system tubing and frame strut functions

•

Engine control unit (ECU)

The VSV system is an integral part of the high pressure compressor stator (HPCS) consisting of IGVs, two VSV actuators and torque shafts, actuation rings, and nonadjustable linkages for each VSV stage. See Figure 5-1.

Variable Stator Vane System

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Figure 5-1. VG System

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The IGV assembly is located at the front of the high pressure compressor (HPC) and is mechanically coupled with the VSV. It allows flow modulation at partial power, resulting in increased engine efficiency. The packager-supplied control is designed to provide excitation and signal conditioning for LVDTs and to control IGV and VSV position by means of closedloop scheduling of IGV actuator position via the servovalve. The VSV packager supplied control system senses gas generator speed (NGG) and compressor inlet temperature (T2) and positions the VSVs. For any one temperature and any one speed, the VSVs take one position and remain in that position until the NGG or T2 changes. The hydraulic pump is supplied with lube oil from the main lube pump. All return flow is bypassed back to the HP side of the gas turbine lube oil pump. The VSV actuators receive HP oil from the VSV servovalve to move the VSVs. Movement of the two actuators is transmitted through a torque shaft and actuation rings to the individual vanes. The VSV actuators, with integral LVDTs, transmit the actual vane position signal to the off-engine control. The VSV servovalve will close the VSVs in the event of loss of hydraulic pressure. 5-3

FUEL SYSTEM

This section provides functional descriptions of the various fuel systems included as standard equipment with the LM2500+ SAC. See Figures 5-2 through 5-10 for fuel system schematics.

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5-3.1

General

Many fuel systems have been developed for the LM2500+ SAC engine to meet the diverse application requirements of the operators. The LM2500+ SAC fuel systems include one or more fuel manifolds, fuel supply tube, and 30 fuel nozzles. The requirements for fuels are provided in Appendix A in Volume I of this manual. The use of unapproved fuels can cause severe damage to the engine. Inquiries concerning fuels should be directed to the packager. 5-3.1.1

Natural Gas

The required supply pressure to the natural gas fuel manifold on the gas turbine is determined by the required maximum power, fuel composition, and supply temperature of the application. The temperature of the gas supply at the fuel manifold connection on the gas turbine must be in the range of 20°F (-6.6°C) above the saturated vapor temperature as a minimum, and 350°F (176.6°C) as a maximum. Based on consideration of control system components however, it is recommended that the maximum gas supply temperature be limited to 150°F (65.5°C). If the supply temperature of the gas is not repeatable on a day-to-day basis, it may be necessary to change the control system starting fuel adjustment or to adjust the supply pressure to the gas turbine to maintain a constant Btu/ft³ supply. Once started the gas turbine will accept variations in supply temperatures of ±20°F (±11°C).

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Figure 5-2. Liquid Fuel System Schematic 5-3.1.2

Fuel Manifold

The fuel manifolds are split ring type and incorporate pressure taps for troubleshooting or continuous read-out. The manifolds distribute fuel to the fuel nozzles. See Figures 5-11 through 5-13 for examples of various LM2500+ SAC fuel manifold configurations. 5-3.1.3

Fuel Nozzles

Fuel is introduced into the combustor via 30 fuel nozzles which are engine mounted and individually removable. The fuel nozzle delivers fuel to the swirl cup to produce a uniformly mixed fuel/air mixture.

5-3.1.4

Fuel Control System

The fuel control system is off-engine mounted and is not supplied as a part of the fuel system. The fuel control regulates fuel flow to the combustor section of the gas generator (GG) to control GG speed. 5-4

STARTING SYSTEM

The starter driv es the engine’s high pressure turbine rotor (HPTR) system through the accessory gearbox (AGB) assembly starter drive pad (Figure 5-14). The starter is required for starting, water-wash, and, when required, for motoring the engine. The gear ratio of the starter to the HPTR is approximately 1:1. Optional air, gas, and hydraulic starters are available from GE. For information on non-GE starters, refer to the packager's manual.

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Figure 5-3. Liquid Fuel System with Water Injection for NOx Suppression and Steam Injection into CDP Ports for Power Enhancement System Schematic 5-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 5-4. Liquid Fuel with Water Injection for NOx Suppression System Schematic 5-6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 5-5. Natural Gas System Schematic 5-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 5-6. Natural Gas with Water Injection for NOx Suppression System Schematic 5-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 5-7. Natural Gas with Steam Injection for NOx Suppression System Schematic

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Figure 5-8. Dual Fuel System Schematic 5-10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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5-9. Dual Fuel with Steam Injection for NOx Suppression System Schematic

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Figure 5-10. Dual Fuel with Water Injection for NOx Suppression System Schematic 5-12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Figure 5-11. Liquid Fuel Manifold Configuration

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Figure 5-12. Natural Gas with Steam Injection for NOx Suppression Fuel Manifold Configuration

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Figure 5-13. Dual Fuel Manifold Configuration

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Figure 5-14. Accessory Gearbox Assembly

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5-4.1

GE Starter Usage

For GE-supplied starters, it is recommended the starter not be engaged unless the HPC shaft is at rest. If necessary, engagement can occur at normal windmilling speeds not to exceed 300 rpm. Engagement of the starter exceeding gas generator speed (NGG) of 300 rpm should be avoided to prevent damage to the starter.

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The maximum supply temperature is 475°F (246.1°C). Air or gas must be dry and filtered to 40 micrometers nominal. The GE supplied air/gas starter duty cycles are as follows:

•

- 45 seconds On, 2 seconds Off for any number of cycles, or

Nominal cutout speed for the GE supplied pneumatic starter is 4,600 rpm (NGG). Cutout speed for the hydraulic starter is 4000 4500 rpm (NGG). If air is used to drive the starter, it can be discharged directly from the starter with no additional piping. If natural gas is used, the exhausted natural gas must be vented to a safe location. For either type of pneumatic starter supplied by GE, the starter lube system is part of the engine system, allowing constant oil flow through the starter. For all other starters, refer to the packager's manual. 5-4.2

Starter Duty Cycles

For information on starter types other than those described here, contact the packager. 5-4.2.1 Air and Gas Starters CAUTION FOR STANDARD OPERATING TIME, EXCEEDING STARTER DUTY CYCLES CAN DAMAGE THE STARTER.

Starting

- 2 minutes On, 5 minutes Off for a maximum of two cycles, or - 2 minutes On, 21 minutes Off for any number of cycles.

•

Motoring - 5 minutes On, 2 minutes Off for a maximum of two cycles, or - 5 minutes On, 18 minutes Off for any number of cycles, or - 10 minutes On, 20 minutes Off for any number of cycles. For 10 minutes of motoring, maximum starter air inlet temperature is 200°F (93.3°C).

5-4.2.2

Hydraulic Starter

On a GE supplied hydraulic starter there are no duty cycle limitations as long as the hydraulic oil temperature is maintained under 140°F (59.9°C). See manufacturer’s recommended duty cycle for other hydraulic starters.

During a normal start, the starter is energized for approximately 40 - 70 seconds (refer to manufacturer’s recommended duty cycle time). Air/gas consumption per start is approximately 120 - 250 lb (54.4 - 113.3 kg), depending on the medium and conditions.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

LUBE SYSTEM

5-5.1 General Description NOTE Use of engine lubrication oil for purposes other than described in this section is not approved. See Figure 5-15 for the lube system schematic. The engine uses lubrication oil to:

•

Lubricate and cool the rotor bearings, sumps, and the inlet, transfer, and accessory gearboxes.

•

Operate the actuators for the IGV and VSV systems.

•

Maintain a supply of oil to the optional pneumatic starter.

The standard engine lube system components include the gearbox-driven engine lube oil supply and scavenge pump, an engine mounted air-oil separator, and the necessary on-engine piping for the system bearings and sumps, for the inlet gearbox, and for the AGB assembly. Oil supply and scavenge temperature sensors are included. The oil temperature sensors are dual-element resistance temperature detectors (RTD). Chip detectors are also included. The packager provides the off-engine system, lube conditioning and storage system, and the necessary flexible lines to interface with the engine. The lube conditioning and storage system includes the lube oil supply filter(s), scavenge oil filter(s), oil cooler , and the storage tank system. The lubrication oil may be used with an AGB assembly-mounted hydraulic pump to provide hydraulic pressure to operate packager-supplied fuel, water, and steam metering valves, required by the system as supplied.

5-5.2 System Flows, Pressures, and Temperatures Table 5-1 provides the parameter values for the oil supply and scavenge, and air/oil separator discharge. Total flow from the oil tank to the engine and return is approximately 18 gal/min (1.14 l/sec) at rated power. For troubleshooting possible operational problems, refer to Chapter 9. 5-5.3

Oil Specification

Type I (MIL-L-7808) or type II oil (MIL-L-23699) is the preferred lubricant for the LM2500+ SAC gas turbine. Minimum oil operating temperature for type I is -20°F (-28.9°C). Type II has a minimum operating temperature of 20°F (-6.7°C). Mixing of type I and II oils should be avoided, however mixing of different brands within a type oil is acceptable. 5-5.4 5-5.4.1

Lube Subsystems Lube Supply Circuit

The oil flow from the supply element of the engine lube pump is approximately proportional to the engine HPTR speed. The pump’s internal relief valve for the lube supply element is set to open at 300 psid (2,068.4 kPa differential) and bypass full flow (at maximum speed) at 400 psid (2,757.9 kPa differential). The pump requires a flooded inlet to maintain prime. Immediately following cold starts, oil pressure at the pump inlet may be as low as 5.0 psia (34.5 kPa absolute). Oil pressure at the pump inlet shall not be less than 12 psia (82.7 psi absolute) when the oil temperature is at normal operating conditions. Oil from the lube and scavenge pump shall be filtered to 10 micron nominal by packager-supplied offengine filters before being returned to the engine lube system. Filters include bypass relief valve with an alarm to alert the operator to impending bypass. Oil filter pressure drop shall not exceed 25 psid (172.4 kPa differential) at full oil flow.

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Oil supplied to the engine should not contain more than 10 percent entrained air on a volume basis. An oil pressure measurement fitting is provided in the engine lube oil supply manifold. Limits in Chapter 7 apply to pressures measured at this fitting. An on-engine temperature sensor is provided for oil supply temperature measurement. Engine oil pressure is a function of HPTR speed and oil supply type and temperature. Refer to paragraph 5-5.3 for oil supply characteristics. Chapter 7 provides requirements for pressure and temperature instrumentation and operation limits. An antistatic leak check valve is provided on the engine to prevent oil drainage from the tank into the engine during shutdown. 5-5.4.2

Scavenge Oil Circuit

Scavenge flow, an air/oil mixture, is approximately proportional to HPTR speed. Scavenge pump capacity is approximately three times that of the oil supply element. Oil returning to the tank is cooled and filtered to 10 micrometers absolute to maintain a clean tank. The filter should include a bypass relief valve and bypass alarm as described for the lube supply circuit. The tank must be vented to ambient through an air/oil demister. An oil pressure measurement fitting is provided in the engine lube oil scavenge system. Limits in Chapter 7 apply to pressures measured at this fitting.

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5-5.4.3

Engine Drains

In normal operation, the drains will have little or no oil flow. A fluid drain collector system should be provided as part of the installation and should comply with all applicable regulations relating to environmental contamination or pollution. It is strongly recommended that provisions be made to isolate the drain lines, when necessary, to enable troubleshooting for excessive drain fluid flow. The collector system must not permit fluids to siphon back into the engine. The AGB assembly drive pad seal drain is a manifold drain for the fuel pump drive pad, the starter drive pad, the shaft seal on the lube/ scavenge pump, and the forward VG pump drive pad. The AGB assembly drain manifold fluid may be lube oil, fuel, or starter hydraulic oil and cannot be returned to the lube storage tank. B- and C-sump drains are combined. 5-5.4.4

Sump Vent Circuit

The engine A-, B-, C-, and D-sumps vent to the engine mounted air/oil separator system. See Figure 5-16 for sump locations and Figure 5-17 for a sump function diagram. The air/oil separator exhaust should be located so as to minimize oil vapor ingestion into the engine inlet system. Oil mist will cause compressor fouling and engine performance loss. The drain lines from the air/oil separator discharge should be routed toward an oil drain in the system.

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Figure 5-15. LM2500+ SAC Lube System Schematic (Sheet 1 of 5)

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Figure 5-15. LM2500+ SAC Lube System Schematic (Sheet 2 of 5)

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Figure 5-15. LM2500+ SAC Lube System Schematic (Sheet 3 of 5)

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Figure 5-15. LM2500+ SAC Lube System Schematic (Sheet 4 of 5)

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Figure 5-15. LM2500+ SAC Lube System Schematic (Sheet 5 of 5) 5-26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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Table 5-1. Gas Turbine Lube/Scavenge System Description

Fluid

Flow

Pressure

Temperature

Lube Pump Inlet

Oil

10 - 18 gal/min (0.63 - 1.14 l/ sec)

0 - 1.0 psig (0 - 6.89 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Lube Supply to Filter

Oil

10 - 18 gal/min (0.63 - 1.14 l/ sec)

15 - 100 psig (103.4 - 689.5 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Engine Lube Supply

Oil

10 - 18 gal/min (0.63 - 1.14 l/ sec)

15 - 68 psig (103.4 - 468.8 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Scavenge Discharge to Filter

Oil

10 - 18 gal/min (0.63 - 1.14 l/ sec)

0 - 25 psig (0 - 172.4 kPa gage)

175 to 275°F (79.4 to 134.9°C)

Air

0.1 - 0.27 lb/min (0.05 - 0.122 kg/ min)

0 - 25 psig (0 - 172.4 kPa gage)

175 to 275°F (79.4 to 134.9°C)

Oil

15 cm³/hr max

2 in. H²O max

200°F max (93.3°C)

Air

0.25 lb/sec max (0.113 kg/sec)

36 in. H²O max

350°F max (176.7°C)

Air/Oil Separator Discharge

NOTE Data provided are normal expected values from idle to maximum power 5-5.5

Sump Pressurization

All sumps are pressurized by stage 9 ejector discharge air. This airflow is of sufficient volume and pressure to maintain a positive airflow inward across the inner seals to the air/oil sump cavity. This positive airflow carries with it any oil on the seals, thus retaining the oil within the inner cavity. Sump pressurization air enters the outer sump cavity through a pressurizing port.

This air then passes across the oil seals into the inner sump cavity, where it is vented to the air/oil separator. Sump pressurization air also passes outward across the outer air seals to the engine cavity. 5-5.6

Oil Consumption

Oil consumption is not expected to exceed 2.0 lb/hr (.91 kg/hr); the average oil consumption is 0.2 lb/hr (.091 kg/hr).

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Figure 5-16. LM2500+ SAC Engine Sumps and Main Bearing Locations

Figure 5-17. Sump Function Diagram (Typical) 5-28 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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5-6 SENSORS AND INDICATING SYSTEMS This section describes the various enginemounted sensors and indicating systems required for normal operation of the LM2500+ SAC. 5-6.1 Gas Generator Speed (NGG) Sensor The engine is equipped with two reluctancetype speed sensors mounted in the AGB section for sensing NGG speed. The speed signal is produced by sensing passing gear teeth frequency on a spur gear in the AGB section. See Figure 5-18. 5-6.2 Power Turbine Speed (NPT) Sensor (Gas Turbine Only) The power turbine (PT) is equipped with two reluctance-type speed sensors or one dual output sensor mounted in the turbine rear frame (TRF) for sensing PT rotor speed. They are transducer assemblies which operate in conjunction with a toothed gear attached to the PT rear shaft. As the gear teeth pass the poles of the transducers, AC voltage is generated. Shims are provided with the single-output transducer to adjust the air gap between the transducer pole and the rotating gear. The dual-output transducer manufacturing tolerances do not require shims to adjust the air gap. See Figure 5-18. 5-6.3

Vibration Sensors

The engine is equipped with two accelerometers, one on the compressor rear frame (CRF) and one on the TRF (GT only). These accelerometers provide protection against selfinduced synchronous vibration. Each sensor is capable of monitoring both high-speed and lowspeed rotor vibration levels.

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5-6.4

Pressure/ Temperature Sensors

5-6.4.1 HPC Total Pressure Probe/ Inlet Air Temperature (P2/T2) The engine is equipped with a dual purpose probe to measure the HPC inlet total pressure (P2) and HPC inlet total temperature (T2). The probe contains a dual-element resistance temperature detector (RTD). The probe is mounted on the CFF. 5-6.4.2

HPC Discharge Temperature (T3)

Two T3 sensors are included as standard equipment. Each T3 sensor is a dual-element chromel-alumel thermocouple with readout capability for each element via integral leads. The sensors are mounted on the CRF. 5-6.4.3

Exhaust Gas Temperature (T5.4)

Eight separate shielded chromel-alumel (type K) thermocouple probes are installed in the turbine mid frame (TMF). The dual-element T5.4 sensor has readout capability for each element which read out via two cable harnesses. See Figure 5-19. 5-6.4.4

Fuel Temperature Sensors (Dual Fuel and Gas/Water Systems)

The gas generator (GG) is equipped with one or two (one for primary fuel manifold and one for secondary fuel manifold on duplex fuel systems) single-element, chromel-alumel (type K) thermocouple probes mounted on the fuel manifold.

Each accelerometer sensor has an integral lead that is routed to one of the electrical panels.

5-29 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 5-18. Speed Pickups.

5-30 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 5-19. Thermocouple Schematic 5-31 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 5-6.4.5 Lube Supply and Scavenge Temperature Five or six dual-element platinum, resistance temperature detectors (RTD) are provided as standard equipment on the engine for measurement of the lube oil supply and scavenge oil temperatures. These RTDs sense temperatures of the bearing lube supply and scavenge from the individual gearbox and sumps (AGB, A, B, C, D). Optional redundant RTDs may also be included. 5-6.4.6

Additional Pressure Parameters

Additionally, the LM2500+ SAC includes provisions for measurement of the following pressure parameters:

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

All sensing lines for flowpath pressure measurement must include provision for preventing water accumulation in the line.

•

Line volume limits exist on the PS3 sensors.

5-6.5

Chip Detectors

The engine is equipped with electrical/magnetic remote-reading chip detectors in the AGB, A-Sump, B-sump, C-sump, and D-sump. Each standard or optional chip detector indicates chip collection when resistance across the detector drops below 100 ohms.

•

Lube oil supply line, one location

•

Lube oil scavenge return line, one location

•

HPC discharge static pressure (PS3), two locations

The position of the HPC VSV is provided to the control and monitoring systems by independent LVDTs. Two actuators in the VSV system are equipped with LVDTs.

•

HP recoup pressure (Prcp), two locations

5-6.7

•

Fuel pressure at fuel manifold inlets, (natural gas and liquid fuel manifolds)

•

Water pressure at fuel manifold inlet, one location

•

PT inlet pressure (PT5.4), one location

The flame sensing system is part of an overall gas turbine (GT) flameout protection system that closes the fuel shutoff valves should combustor flameout occur. An ultraviolet flame detector indicates the loss of flame in the engine combustion system for engine control system logic use in monitoring.

•

PT balance piston pressure (PTB), one location (6-stage PT applications only)

The lube oil and fuel supply pressure indications can be used for condition monitoring or troubleshooting. PS3, Prcp, and PT5.4 are vital to engine operation and are an integral part of the packager-supplied control system. For these parameters, the packager is responsible for sensors, leads, and readout devices.

5-6.6

Variable-Geometry Position

Flame Sensors

The flame detector hardware consists of two ultraviolet sensor assemblies (packager supplied) and two flame viewing window assemblies with sensor brackets, mounted on two holes in the CRF.

5-32 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

5-7

ELECTRICAL SYSTEM

The engine electrical system consists of the ignition system and the cabling for control and instrumentation. The system is designed for high reliability and ease of maintenance by utilizing integral lead sensors or on-engine harnesses. 5-7.1

Ignition System NOTE

Refer to Volume II, WP 103 00, Igniter Removal/ Installation Package. The ignition system consists of one (a second igniter optional) high-energy igniter, one highenergy capacitor-discharge ignition exciter, and the interconnecting cables. The ignition cable is interconnected directly between the package-mounted exciter and the igniter, which are mounted on the engine CRF. During the start sequence, fuel/air mixture is ignited by the igniter, which is energized by the ignition exciter. One or both igniters (if two igniters are installed) may be energized; alternating igniter use is recommended. Once combustion becomes self-sustaining, the igniter is de-energized. The maximum duty cycle is a maximum of 90 seconds ON and two start cycles within a 30 minute period. 5-7.2

Cabling

The LM2500+ SAC requires electrical cables for interconnection between the packagemounted junction boxes and the engine. Instrumentation leads must be isolated from power leads, shielded, and run in conduits carrying only other very low level leads.

GEK 105054 Volume I

5-8

BLEED AIR SYSTEM

5-8.1 Compressor Discharge Pressure Bleed The optional CDP bleed manifolds combine four compressor case bleed ports into two interfaces. The purchaser is required to provide the interconnecting piping between these interfaces and the customer supplied CDP bleed valve. 5-9

6-STAGE POWER TURBINE (MODEL PK) BALANCE PISTON SYSTEM

Stage 13 HPC air is extracted from near the 8 o’clock position on the HPC rear stator case. This air is piped aft to the TRF, strut No. 8 and is used to pressurize the balance piston system cavity. The system is designed to maintain proper thrust loads on the No. 7B bearing during gas turbine operation. Loss of, or low pressure, to the system can result in premature No. 7B bearing distress. The system provides a pressure tap at TRF strut No. 2 for monitoring cavity pressure. The system has the capability to adjust supply pressure by using different size orifice plates. 5-10

HIGH PRESSURE RECOUP SYSTEM

The CRF B-sump pressurization system is isolated from the HPC by the CDP and vent labyrinth seals. These seals serve to form HP recoup chamber. The HP recoup airflow results from compressor discharge air leaking across the CDP seal. The CDP seal leakage air is directed to the TMF cavity for purge. HP recoup orifice plates are used for adjusting 4B thrust balance by adjusting the HP recoup pressure.

5-33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 5-20. Gas Generator Pneumatic Piping - Left Side View

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GEK 105054 Volume I

Figure 5-21. Gas Generator Pneumatic Piping - Right Side View 5-35 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

5-11 AIR SYSTEM TUBING AND FRAME STRUT FUNCTIONS The LM2500+ SAC has external pneumatic tubing and four frames with strut locations. The struts are located in the CFF, CRF, TMF, and TRF (for GT only). See Figures 5-20 and 5-21 for tubing locations and Figure 5-15 (Sheet 1) for strut functions. 5-11.1

A-, B-, C-, and D-Sump Vents

All sumps and gearbox vent manifolds are piped on the engine together and directed to the gearbox air/oil separator. The air discharge from the separator is typically vented to the atmosphere via the exhaust duct or a separate demister. An overboard drain is required at the low point of the piping. 5-12

ENGINE CONTROL UNIT

The ECU, supplied by the packager, performs the fuel, VG scheduling, engine start and stop sequencing, and data acquisition for support of the engine monitoring system.

5-36 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 6 Service and Support Requirements 6-1

PURPOSE AND SCOPE

This chapter defines the following service and support requirements associated with the LM2500+ SAC gas generator (GG)/gas turbine (GT):

•

Shipping

•

Storage

•

Installation/removal

•

Auxiliary systems

•

Support services

•

Maintenance

The information provided is general but not all-inclusive. References are made to other chapters of Volume I and to specific work packages (WP) in Volume II that cover these topics in detail. 6-2

SHIPPING

The engine is shipped from the factory as a complete assembly, including the engine, fuel manifolds, engine-mounted accessories, external configuration hardware, and enginemounted sensors. If the gas generator/gas turbine and fuel system are removed from the enclosure in preparation for shipment, the fuel system must be properly drained and purged of gas or liquid fuel prior to removal as covered in WP 300 00 or WP 301 00.

NOTE

•

Both the engine and power turbine (PT) containers can be air-shipped on the 747F, L1011, or C130 aircraft. The PT can also be air-shipped on DC10CF, C130, A300C, and A310C/F aircraft.

•

For highway shipment, the use of a pneumatic suspension trailer or car is required.

6-2.1

Engine Shipment CAUTION

MAXIMUM ALLOWABLE SUSTAINED VIBRATION OR REPETITIVE SHOCK LOAD ON A NONOPERATING (NOT IN CONTAINER) ENGINE IS 0.5 G AT ANY FREQUENCY, IN ANY DIRECTION. EXCEEDING LIMIT COULD DAMAGE ENGINE. The maximum allowable loads into the container are 3.5 G vertically upward, 2.5 G vertically downward, 2.0 G fore and aft, and 1.5 G laterally. In the event that the engine requires repair at a designated repair facility, it should be shipped to the facility in the shipping container. Installation of the engine in the shipping container is covered in WP 502 00.

The fuel manifolds for the LM2500+ SAC engine are shipped with the GG/GT inside the shipping container.

6-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 6-2.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Engine Shipping Container

The engine assembly is shipped in a reusable metal container that measures approximately 219 inches (556.3 cm) long by 102 inches (243.8 cm) wide by 99 inches (251.5 cm) high. The empty container weighs approximately 12,000 pounds (5,443.1 kg). The container is equipped with shock mounts to avoid damage to the engine bearings during shipment. It has a pressure relief valve for controlled breathing, humidity indicators, and a desiccant container for a controlled environment. See Figure 6-1. Weight of the container and engine assembly as shipped from the factory is approximately 20,181 pounds (9,154.0 kg). The shipping container is equipped with a vibration-attenuation support system, which protects the engine from damage when subjected to repetitive or nonrepetitive loads at the container mount interface locations during transportation and handling. 6-2.3

Power Turbine Shipment

In the event that the PT requires repair at a designated repair facility, it should be shipped to the facility in the shipping container. Installation of the PT in the shipping container is covered in WP 503 00. 6-2.4

Power Turbine Shipping Container

to the bearings during shipment. It has a pressure relief valve for controlled breathing, humidity indicators, and a desiccant container for a controlled environment. See Figure 6-2. The weight of the container is approximately 2,700 pounds (1,224.6 kg) empty and 5,800 pounds (2,630.8 kg) loaded. 6-2.5

Enclosure Shipping

In the event that the engine is to be shipped already mounted in the enclosure (package), the design of the enclosure shall be checked to verify that it has equivalent shock and vibration attenuation capability as the container. 6-2.6

Highway Shipping CAUTION

FAILURE TO COMPLY WITH THIS REQUIREMENT MAY RESULT IN DAMAGE TO THE ENGINE BEARINGS. Shipping of the engine/container system requires the use of a pneumatic suspension trailer for highway shipment. The engine container shall be secured to the trailer in such a manner that the shock-absorbing capability of the container is not disabled. Tie-down points are provided on both sides of the lower portion of the container, fore and aft.

NOTE For GTs with a 2-stage high speed PT, refer to GEK 105052 and GEK 105053 manuals. The PT, consisting of the rotor, stator, turbine rear frame (TRF), and forward adapter, can be transported in a unique reusable metal shipping container. This container is approximately 79 inches (200.6 cm) long by 85 inches (215.9 cm) wide by 73 inches (185.4 cm) high. Similar to the engine assembly container, it is equipped with shock mounts to avoid damage

6-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 6-1. Engine Shipping Container 6-3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 6-2 Power Turbine Shipping Container (Typical) 6-4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

6-2.7

On-Site Transportation CAUTION

FAILURE TO COMPLY WITH THIS REQUIREMENT MAY RESULT IN DAMAGE TO THE ENGINE BEARINGS. If the engine is removed from the container or enclosure and transported using the LM2500+ SAC maintenance dolly, speed during that movement shall be limited to a maximum of 5 mph. Figure 6-3 illustrates the LM2500+ SAC universal maintenance dolly. 6-3

STORAGE

The engine is prepared for long-term storage when shipped from the factory or from a repair facility. Refer to WP 500 00 and WP 501 00 for preservation and storage of GT, GG, and PT. Long-term storage includes the following elements:

GEK 105054 Volume I

6-4.1

Installation/Removal Methods

Installation of the engine into, or removal from, the enclosure will normally be accomplished by one of two methods listed below. An on-site mobile crane and specific tooling may be required, depending on package design. If the fuel manifolds or other fuel system components are shipped with the engine, the system must be properly drained and purged of gas or liquid fuel consistent with regulatory requirements for hazardous materials prior to installation in the shipping container. Separate fuel system drain and purge requirements for both ground and air shipment are included in WP 300 00 and WP 301 00.

•

Overhead installation/removal through an opening in the top of the enclosure requires the use of an on-site or mobile crane.

•

Side installation/removal requires the engine to be lifted using an on-site or mobile crane and the ground handling points, so it can be moved laterally into/ from the enclosure.

•

Lubrication system is flushed with rust preventative.

•

Inlet is covered.

6-4.2

•

Exhaust is covered.

•

Lines are connected or capped.

The following information is provided for installation, removal, and on-site movement planning.

•

Container is sealed airtight and provided with desiccant for humidity control.

•

Should temperature, pressure, and/or humidity conditions be such that the desiccant seen through the container inspection port is blue, then the container must be serviced in accordance with WP 500 00 and WP 501 00. 6-4

Size/Weight

Engine Length (GT): 214.725 inches (545.40 cm), from front of the bullet nose to end of the output shaft

INSTALLATION/REMOVAL

This section provides general descriptions of procedures and elements requiring consideration during installation and removal of the engine from the enclosure. Purchaser is responsible for installation/removal processes which will be dependent on enclosure design. For removal of engine from shipping container, refer to WP 502 00. 6-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 6-3 Maintenance Dolly (Sheet 1 of 2)

6-6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 6-3 Maintenance Dolly (Sheet 2 of 2)

•

PT Length: Approximately 58.8 inches (149.4 cm), not including the exhaust diffuser

•

Engine Length (GG): 161.23 inches (409.5 cm), from front of bullet nose to aft flange of turbine mid frame

•

Engine Weight without fuel system (GT): 8,181 pounds (3,710.8 kg)

•

PT Weight: 2,830 pounds (1,283.7 kg)

•

6-4.2.1 Major Component Weights The average weights of the major GG/GT components are:

•

Inlet Gearbox: 38 pounds (17.2 kg)

•

Transfer Gearbox: 245 pounds (111.1 kg)

•

Compressor Front Frame (CFF): 517 pounds (234.5 kg)

Engine Weight without gas manifold (GG): 4,735 pounds (2,147.8 kg)

•

Compressor Rotor: 552 pounds (250.4 kg)

The estimated center of gravity for the GG is axial station 98.4 inches (249.9 cm). The estimated center of gravity for the GT is axial station 136.8 inches (347.5 cm). Both the GG and GT estimations for the center of gravity are without the fuel system.

•

Compressor Stator Casing: 370 pounds (167.8 kg)

•

Compressor Aft Case: 93 pounds (42.2 kg)

6-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

•

Compressor Rear Frame: 421 pounds (191.1 kg)

•

Combustor: 120 pounds (54.4 kg)

•

High Pressure (HP) Turbine Rotor: 419 pounds (190.1 kg)

•

Stage 1 HP Turbine Nozzle: 68 pounds (30.8 kg)

•

Stage 2 HP Turbine Nozzle: 127 pounds (57.6 kg)

•

Turbine Mid Frame: 580 pounds (263.1 kg)

•

Low Pressure (LP) Turbine Rotor: 1,095 pounds (496.6 kg)

•

LP Turbine Stator: 601 pounds (272.6 kg)

•

TRF: 1,071 pounds (485.7 kg)

•

High Speed Coupling Shaft Forward Adapter: 91 pounds (41.3 kg)

6-4.3

Engine Mount Attachments

The purchaser is responsible for mounting provisions for the GT engine. The mounting system shall provide, as a minimum, provisions for:

•

The dead weight of the GT/ GG including fuel system

•

The torque reaction imposed by power extraction

•

Engine self-induced vibration and two blade-out loads

•

Exhaust gas loads

•

Flexible coupling loads

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

•

Output shaft loads

•

Any other induced loading

The GT engine’s mount locations are as follows:

•

The forward four mount points are located on the CFF (two top mounts and two bottom mounts). CAUTION FAILURE TO HOLD RADIAL AND AXIAL DIMENSIONS WILL RESULT IN FUEL LINE FAILURES.

•

The TRF is equipped with three mount attachments, as shown in Figure 6-4. These mounts are designed to provide for vertical and lateral support of the engine.

•

Mounts for the packager supplied exhaust duct are designed to maintain the centerline of the exhaust duct and take axial, vertical, and horizontal loads.

6-4.4

Flange Interfaces

For installations with an axial inlet, a packager-supplied air inlet bellmouth is independently supported at the forward enclosure bulkhead. The flowpath between the bellmouth and the engine is formed by a liner following the contour of the bellmouth. Any gap outboard of this liner must be sealed to prevent inflow of ambient air. The aft or exhaust interface flanges are on the TRF. The outer and inner flanges mate with the packager's exhaust outer and inner flowpath diffuser. These joints normally incorporate a piston ring assembly to accommodate thermal growth of the engine.

6-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 6-4 Engine Mount Diagram (Sheet 1 of 2) 6-9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 6-4 Engine Mount Diagram (Sheet 2 of 2) 6-10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

6-5

AUXILIARY SYSTEMS

Provision is made in the packager's design to accommodate the following conditions and auxiliary requirements. 6-5.1

Inlet System

The packager is responsible for providing an inlet air system which provides clean air into the GT engine with minimum pressure loss. All fasteners (nuts, bolts, rivets, etc.) in, or having the potential for entry into the inlet airflow path, must be positively retained to prevent loosening and possible foreign object damage (FOD) to the GT. The use of a four mesh screen is strongly recommended in order to provide debris free airflow into the GT. An 800 micron nylon mesh screen is additionally recommended for initial operation.

GEK 105054 Volume I

In the event it is necessary to continue operation through periods of severe conditions during which the above contaminant levels have been exceeded, it will be necessary to borescope the high pressure turbine blades to ensure that the leading edge cooling holes are open. For operation in marine environments, sodium entering the engine should not exceed 0.00045 parts/million (ppm) average or 0.003 ppm maximum. These limits apply to both air entering the engine and to the cooling air supply. Depending on fuel characteristics, inlet air contamination may require restriction below the levels stated above. The combination of entrained sodium entering the engine through inlet air and fuel contamination must not exceed 0.2 ppm.

The air entering the inlet of the engine must meet the following conditions:

The maximum allowable liquid water content in the inlet air is 0.5 percent of the inlet airflow weight (approximately 350 lb/sec [158.7 kg/sec]) at air inlet temperatures of 42°F (5.6°C) and above. At temperatures below 42°F (5.6°C), no liquid water content is allowed due to the potential for icing.

•

6-5.1.2

6-5.1.1

•

Air Filtration

95 percent of the time: must not contain solid particles exceeding 0.004 grains/1,000 ft³ (0.00026 grams/1,000 m³) 5 percent of the time: must not contain solid particles exceeding 0.04 grains/1,000 ft³ (0.0026 grams/1,000 m³)

Under severe conditions, such as dust storms and sand storms in desert environments, it is recognized that commercially available air filtration systems may result in these limits being exceeded for limited periods. To minimize the effect on engine life, operation under such conditions should be avoided whenever practicable.

Anti-Icing

Under certain conditions, as a function of temperature and humidity, ice can form at the engine inlet, be ingested into the flow path, and cause FOD. The engine is not equipped with an integral anti-icing protection system. GE does recommend, however, that such a system be installed and operational for any installation operating in a climate where the temperature can fall below 40°F (4.4°C). The anti-icing system, whether installed by the operator/user or the packager, must ensure that the humidity and temperature measured at the engine inlet are within the limits shown in Figure 6-5.

6-11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 6-5 Temperature Limits 6-5.2

Exhaust System

The packager is responsible for providing an exhaust collector assembly for the LM2500+ SAC engine. 6-5.3

Secondary Cooling Air

In order to maintain enclosure and engine component temperatures at acceptable limits, secondary cooling air must be provided. CAUTION AIR CONTAINING SALTS OR OTHER CORROSIVE ELEMENTS HAVE A HARMFUL EFFECT ON THE ENGINE AND MUST BE FILTERED OR WASHED PRIOR TO USE IN SECONDARY COOLING AIR CIRCUITS.

Secondary cooling air must be filtered so that solid material in the air does not exceed 0.2 grains/1,000 ft³ (0.013 grams/ 28.32 m³) of air, and the size and density distribution should be such that no more than 5 percent (by weight) of the solid particles are 10 micrometers or greater in size. 6-6

SUPPORT SERVICES

The following packager/operator-supplied support services are required for operation of the engine as part of the overall system:

•

Unloading and installation of all equipment

•

Fuel supply to the engine in accordance with the applicable GE specifications

6-12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

•

Verification of site conditions, including inlet air quality and fuel quality

•

Lubrication system external to the engine

•

Fuel metering and control systems; engine speed-governing and protection systems

•

Engine base, mounting structure, sound enclosure, inlet system, exhaust system, and rear flexible drive coupling

•

Fire detection and protection system

•

Water supply and control system for waterwashing of the engine

•

Anti-icing system (as applicable)

•

Vent and drain system

•

Electrical power supply

•

Control and instrument panel, including all interconnecting wiring and piping

•

Water or steam supply and control system (if applicable)

•

Air, natural gas, or hydraulic supply to the starter and discharge ducting or piping from the starter

•

Personal safety protection features

•

Condition-monitoring system

GEK 105054 Volume I

6-7

MAINTENANCE

The engine is designed and mounted in the enclosure with consideration of site maintenance requirements. Maintenance activity on the engine falls into three following categories: Level 1: Any maintenance activity associated with the exterior of the engine up to and including removal and reinstallation of the complete engine assembly. Level 2: Any maintenance activity associated with the interior or flowpath of the engine. This includes removal and replacement of complete module assemblies such as the high pressure compressor, accessory gearbox, high pressure turbine, and other components. Depot: Any activity that requires detailed teardown and/or test verification that can only be accomplished in a designated repair facility. All levels 1 and 2 maintenance activity is detailed in individual work packages contained in Volume II of this manual. GE recommends users have level 1 tooling and spare parts on site. GE also provides training for operators (familiarization and level 1 maintenance) on the LM2500+ SAC engine.

6-13/(6-14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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GEK 105054 Volume I

CHAPTER 7 Installation/Initial Startup and Engine Operation 7-1

PURPOSE AND SCOPE

This chapter covers safety considerations, installation, pre-startup inspections, and verification test procedures for the engine following initial installation and/or subsequent removal and replacement of the engine or major components. This chapter also covers general operating procedures that are typical of any LM2500+ SAC -powered package. The following topics are all directed at ensuring that the operating, maintenance and support personnel have a source of technical information associated with the engine and its operation as installed in an enclosure. It provides the operator with specific requirements concerning the air, oil, and fuel used during normal operation and is intended to ensure that the engine is operating in the environment and under conditions for which it was designed. Some of the information contained in this chapter is also provided, in whole or part, in other chapters. Redundancy is used to provide as much specific detail as required. It is also possible that the information may not provide for every variation in installation, equipment, or contingency to be found in conjunction with engine operation. Configuration and system procedures may vary from package to package and with the packager-supplied control system. Prior to operation of the engine, the site operators should be thoroughly schooled in both normal and abnormal (emergency) operations and the control system action/reaction to these conditions. Additional information can be provided by the packager or by General Electric Marine and Industrial Engines (GE/M&IE).

7-2

SAFETY

General safety precautions are defined in Chapter 1. The following safety considerations should be observed by operators and support personnel working on the engine:

•

The outside surfaces of the engine are not insulated. Adequate precautions should be taken to prevent personnel from inadvertently coming in contact with hot surfaces

•

The engine is a source of considerable noise. It will be necessary for personnel working on it, or in its vicinity, to wear proper ear protection equipment when the engine is operating

•

High speed rotating components are inherent in any gas turbine (GT) engine. In the remote case of parts failure, the casing may not contain major compressor or turbine disk failures. Personnel should not be permanently stationed in, or near, the plane of the rotating parts

•

Rotating parts of the starter operate at a very high speed. To guard against the remote case of a parts failure, personnel should not be stationed near the starter during start, motoring, or purge cycles

•

The low-pressure, high-velocity airflow created by the compressor can draw objects and personnel into the engine. The use of an inlet screen or other protective measure is strongly recommended

•

Suitable fire protection equipment should be provided for the installation. Carbon dioxide, halides, fog, water, or chemical fire extinguishing systems may be used. Discharge of fine chemical or water mists

7-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

directly on engine casings is permissible. The use of chemical fire extinguishing media will require the disassembly of the engine for cleaning

•

Fire extinguishing media can be toxic or smothering. Care must be taken to ensure that all personnel are clear of the enclosure prior to fire extinguisher system activation. Failure to comply may result in injury or death to personnel remaining inside the enclosure

•

Suitable explosive mixture sensing devices should be provided to sense any leakage of fuel and to shut down the engine if leakage is present

•

Personnel entry into the engine enclosure during operation at engine speeds above idle should be prohibited. Signs or placards should be posted at the enclosure access doors and should clearly state the hazardous conditions that exist in the enclosure during operation above idle

7-2.1

SECONDARY AIR TO THE ENCLOSURE SHALL BE SHUT OFF

•

THE ENCLOSURE DOOR SHALL BE KEPT OPEN. IF THE ENGINE IS OPERATING, AN OBSERVER SHALL BE STATIONED AT THE ENCLOSURE DOOR

•

ALLOW THE ENGINE TO COOL DOWN BEFORE ENTERING THE ENCLOSURE. AVOID CONTACT WITH HOT PARTS; WEAR THERMALLY INSULATED GLOVES IF NECESSARY

•

EAR PROTECTION SHALL BE WORN IF THE ENGINE IS OPERATING

•

DO NOT REMAIN IN THE ENCLOSURE OR IN THE PLANE OF ROTATION OF THE STARTER WHEN STARTING OR MOTORING THE ENGINE

•

WHEN PERFORMING MAINTENANCE ON ELECTRICAL COMPONENTS, AVOID SHOCKS AND BURNS BY TURNING OFF ELECTRICAL POWER TO THOSE COMPONENTS, EXCEPT WHEN NECESSARY TO TAKE VOLTAGE MEASUREMENTS

Engine Maintenance/ Inspection Precautions WARNING

•

WHEN ENTERING THE ENGINE ENCLOSURE, THE REQUIREMENTS LISTED BELOW MUST BE MET.

•

THE ENGINE SHALL BE SHUT DOWN OR LIMITED TO IDLE POWER. REFER TO THE PACKAGER'S MANUAL

•

•

THE FIRE EXTINGUISHING SYSTEM SHALL BE MADE INACTIVE ACCORDING TO THE PACKAGER'S INSTRUCTIONS

WARNING

•

TAG ELECTRICAL SWITCHES OUT OF SERVICE TO PRECLUDE INADVERTENT ACTIVATION. TAG THE ENGINE OPERATING CONTROLS DO NOT OPERATE TO PREVENT STARTING DURING A DESIRED SHUTDOWN CONDITION

7-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

•

DO NOT USE ENGINE PIPING, CABLES, INSTRUMENTATION LEADS, OR OTHER EXTERNAL HARDWARE AS HAND OR FOOTHOLDS WHEN PERFORMING MAINTENANCE ACTIVITY ON THE ENGINE. THESE HARDWARE ITEMS ARE NOT DESIGNED TO SUPPORT LOADS OTHER THAN THOSE ASSOCIATED WITH ENGINE OPERATION

7-3

INSTALLATION

If not already installed in the package, the engine should be installed according to the packager's requirements and specifications. For specific details on engine installation procedures and tools, refer to work package (WP) 300 00, WP 301 00, WP 302 00, WP 303 00, and WP 001 00 as well as the packager's manual. 7-3.1

Site Information

Refer to the packager's manuals and drawings for installation design details. 7-3.2

Installation Procedure NOTE

•

•

Use new preformed packings, seals, or gaskets at all connections where they are required. Refer to Chapter 6 and to the appropriate packager’s manual for mounting points, interface locations, and component weights.

a.

Install and align engine per packager's instructions.

b.

Install starter onto accessory gearbox and configure the engine as required by the site and packager's instructions.

c.

Install ignition leads per WP 103 00.

GEK 105054 Volume I

7-3.3

Equipment Protection

The engine is provided with covers that protect various operational interfaces during shipping, handling, installation, and maintenance activity. These covers are provided and used to protect the engine from potential FOD (foreign object damage) caused by handling and objects such as dirt, weld beads, tools, rags, nuts, and bolts. 7-3.3.1

Inlet Cover

The engine is shipped with an inlet cover that should only be removed when the engine is installed in the package. This cover should be retained by the operator and installed for engine protection any time the inlet connection is broken. 7-3.3.2

Exhaust Cover

The engine is shipped with an exhaust cover which should be left in place until the engine is mated to its interface. Similar to the inlet cover, this cover should also be retained by the operator and installed any time the engine is disconnected. 7-3.3.3

Electrical, Fluid, and System Interface Covers

The engine is shipped with protective covers over all electrical, fluid, and system interfaces. These covers are in place to prevent handling damage (threads, pins, etc.) and fluid or system piping contamination. A supply of these covers should be maintained by the operator for use during maintenance activities that require electrical leads, fluid piping, or system piping to be disconnected. 7-3.4

Engine Protection

The LM2500+ SAC is a reliable, durable engine designed to operate in an industrial atmosphere for extended periods of time. However, the operator needs to follow certain basic procedures in order to enhance the engine's operational capability. 7-3

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 7-3.4.1

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Lubricating Oil Requirements

Lubricating oil is used to lubricate bearings, gears, and some splines. Additionally, lube oil is used in the variable-geometry control actuation system. The oil must be temperature-controlled and kept clean per the following requirements in order to adequately perform its function. a.

The requirements for gas turbine/gas generator lubricating oil are provided in Appendix A7.

b.

Minimum temperature at start is 20°F (-6.7°C) for type II (MIL-L-23699) oil and -20°F (-28.9°C) for MIL-L-7808.

c.

Minimum allowable temperature for operation at idle or above is 90°F (32.2°C).

d.

Normal supply temperature should be maintained between 140 to 160°F (59.9 to 71.1°C).

e.

Minimum supply pressure above 4,500 rpm or idle is 8 - 15 psig (55.2 - 103.4 kPa gage). Above 8,000 rpm, the supply pressure is > 15 psig (103.4 kPa gage).

f.

Mixing of different types (Type I versus Type II) of oils is not allowed. Mixing of oil brands of the same type is acceptable. Topping off when changing oil brands of the same type is the preferred method, but indiscriminate changing is not recommended.

CAUTION FOLLOWING THIS FLUSHING, THE SYSTEM FILTER ELEMENTS SHOULD BE REMOVED OR REPLACED TO AVOID ENGINE CONTAMINATION. h.

In the event of a failure during site operation that involves the engine lube system, the complete system should be disconnected, drained, and cleaned as described in the preceding step. This procedure should be followed whether the engine is removed and replaced or repaired on-site.

i.

Engine oil should be filtered to 10 microns, nominal.

7-3.4.1.1 Lube Oil Pressure Corrections For Industrial LM2500+ SAC Gas Turbines and Gas Generators Tables 7-1 through 7-4 and Figures 7-1 through 7-4 provide corrections and limits for lube supply pressure. NOTE

•

There can be significant site-to-site variation in typical lube system parameters based on variations in package designs, lube filters, and site engine operating profiles. A significant rise in lube scavenge temperature, or scavenge filter ΔP, can occur without reaching the recommended alarm or shutdown limits. It is possible for substantial secondary damage to occur in the time following a significant increase in scavenge temperature or filter ΔP prior to reaching the alarm/shutdown limits.

•

GE recommends that operators establish baseline readings for:

CAUTION FAILURE TO PROPERLY MAINTAIN A CLEAN LUBE SYSTEM COULD RESULT IN PREMATURE FAILURE OF THE GT OR COMPONENTS. g.

Before the initial motoring and start of an engine in a new installation or following work on the lube system, the lube oil conditioning and storage system and all of the various circuits should be flushed to ensure cleanliness.

1. Lube scavenge temperatures for all engine sumps and the gearbox

7-4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

2. Lube scavenge filter Δ pressure (clean filter at max power and normal temperature conditions)

•

GE recommends that operators set new lube scavenge temperature and scavenge filter ΔP control limits for alarm and automatic shutdown based on increases in temperature or filter ΔP relative to the established baseline.

Recommended Limits for:

Alarm

Shutdown

Lube Scavenge Temperature

Baseline +20°F (11°C)

Baseline +40°F (22°C)

Lube Scavenge Filter ΔP

Baseline +100%

Baseline +150%

7-3.4.1.2 Lube Supply Pressure at Pressure Tap vs. Gas Generator/Gas Turbine Speed Figures 7-5 (Sheet 1 of 4) through 7-5 (Sheet 4 of 4) provide nominal lube supply pressures at pressure tap vs. gas generator (GG)/GT speed and lube supply temperature for SAC models. 7-3.4.2

Air

Maximum airflow through the LM2500+ SAC engine is approximately 185 lb/sec (83.9 kg/sec) and is filtered by the inlet system to meet the following requirements:

•

95 percent of the time: must not contain solid particles exceeding 0.004 grains/1,000 ft³ (0.0003 g/28.32 m³)

•

5 percent of the time: must not contain solid particles exceeding 0.04 grains/1,000 ft³ (0.003 g/28.32 m³)

GEK 105054 Volume I

•

When operating in a marine environment, sodium (from air or water) entering the engine should not exceed 0.00045 parts/ million (ppm) average, or 0.003 ppm maximum

•

The maximum allowable liquid water content in the inlet air is 0.5 percent of the inlet airflow weight at inlet air temperatures of 42°F (5.6°C) and above. Below 42°F (5.6°C), no liquid water content is allowed

7-3.4.3

Gas Fuel

Gas fuel should be what is known in industry as dry gas. That is, the gasoline vapor in 1,000 ft³ (28.3 m³) of gas at standard conditions (60°F and 30 in. Hg abs [15.5°C and 764 mm Hg]) should not exceed 0.1 gal (0.37 l) of liquid. Liquid hydrocarbons in gas fuel can cause surges in operation or engine damage. Therefore, gas fuel mixtures must be maintained at temperatures 50°F (27.7°C) above their dewpoint at the engine fuel manifold inlet. The temperature of the gas fuel should not exceed 300°F (148.8°C) at the gas fuel manifold inlet. The requirements for natural gas are provided in Appendix A1. 7-3.4.3.1

Liquid Fuel

The requirements for liquid fuel are provided in Appendix A4. The fuel shall be filtered to 20 microns absolute. 7-3.4.4

NOx Suppression

The requirements for water or steam injection for NOx suppression are provided in Appendices A5 and A6.

7-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 7-1. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 45-55 psig (310-279 kPa). Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

100 (38)

- 7.74

- 8.93

-10.14

-11.35

-12.58

-13.81

-15.05

-16.31

-17.57

-18.85

9000 -20.14

110 (43)

- 3.52

- 4.64

- 5.76

- 6.89

- 8.03

- 9.18

-10.34

-11.51

-12.69

-13.88

-15.08

120 (49)

- 0.02

- 1.10

- 2.19

- 3.30

- 4.42

- 5.54

- 6.64

- 7.75

- 8.86

- 9.98

-11.11

130 (54)

+ 2.91

+ 1.93

+ 0.94

- 0.06

- 1.07

- 2.09

- 3.12

- 4.14

- 5.16

- 6.19

- 7.23

140 (60)

+ 5.82

+ 4.92

+ 4.01

+ 3.11

+ 2.19

+ 1.27

+ 0.33

- 0.60

- 1.55

- 2.50

- 3.46

150 (66)

+ 8.60

+ 7.77

+ 6.93

+ 6.09

+ 5.24

+ 4.38

+ 3.52

+ 2.65

+ 1.77

+ 0.89

160 (71)

+11.13

+10.34

+ 9.55

+ 8.75

+ 7.95

+ 7.14

+ 6.32

+ 5.50

+ 4.67

+ 3.84

0 +3.00

170 (77)

+13.35

+12.61

+11.87

+11.12

+10.33

+ 9.52

+ 8.71

+ 7.90

+ 7.07

+ 6.24

+5.40

180 (82)

+15.07

+14.33

+13.58

+12.83

+12.07

+11.31

+10.54

+ 9.77

+ 8.99

+ 818

+7.36

190 (88)

+16.53

+15.80

+15.06

+14.31

+13.55

+12.77

+11.98

+11.18

+10.38

+ 9.56

+8.74

200 (93)

+17.57

+16.84

+16.10

+15.35

+14.60

+13.83

+13.06

+12.27

+11.46

+10.65

+9.83

210 (99)

+18.40

+17.67

+16.93

+16.18

+15.42

+14.65

+13.88

+13.10

+12.31

+11.51

+10.71

220 (104)

+19.08

+18.36

+17.64

+16.90

+16.16

+15.41

+14.65

+13.89

+13.12

+12.34

+11.55

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-12.43

-22.74

-24.05

-25.37

-26.70

-28.04

-29.39

-30.76

-32.13

-33.50

110 (43)

-16.30

-17.52

-18.74

-19.99

-21.27

-22.56

-23.86

-25.18

-26.51

-27.85

120 (49)

-12.25

-13.39

-14.55

-15.17

-16.87

-18.05

-19.23

-20.42

-21.62

-22.83

130 (54)

- 8.28

- 9.33

-10.38

-11.43

-12.49

-13.56

-14.64

-15.72

-16.81

-17.91

140 (60)

- 4.43

- 5.39

- 6.36

- 7.33

- 8.31

- 9.30

-10.29

-11.29

-12.30

-13.31

150 (66)

- 0.09

- 1.81

- 2.72

- 3.64

- 4.56

- 5.49

- 6.53

- 7.37

- 8.32

- 9.27

160 (71)

+ 2.16

+ 1.31

- 0.46

- 0.40

- 1.27

- 2.16

- 3.09

- 4.02

- 4.96

- 5.91

170 (77)

+ 4.55

+ 3.70

+ 2.84

+ 1.99

+ 1.12

+ 0.25

- 0.62

- 1.05

- 2.39

- 3.28

180 (82)

+ 6.53

+ 5.69

+ 4.84

+ 3.99

+ 3.13

+ 2.24

+ 1.34

+ 0.43

- 0.48

- 1.41

190 (88)

+ 7.91

+ 7.08

+ 6.23

+ 5.38

+ 4.52

+ 3.66

+ 2.77

+ 1.86

+ 0.95

+ 0.03

200 (93)

+ 9.00

+ 8.16

+ 7.31

+ 6.45

+ 5.59

+ 4.72

+ 3.85

+ 2.96

+ 2.07

+ 1.17

210 (99)

+ 9.90

+ 9.08

+ 8.25

+ 7.42

+ 6.57

+ 5.72

+ 4.86

+ 4.00

+ 3.12

+ 2.24

220 (104)

+10.76

+ 9.95

+ 9.14

+ 8.33

+ 7.50

+ 6.67

+ 5.83

+ 4.98

+ 4.13

+ 3.26

NOTE:

Oil MIL-L-23699

Example:

Observed NGG 8700 RPM Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -4.14 psig (28.5 kPa) Corrected Pressure 56 -4.14 = 51.86 psig (357.6 kPa)

7-6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-1. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil 7-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 7-2. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 37-45 psig (255-310 kPa). Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

- 4.69

- 5.36

- 6.58

- 7.54

- 8.51

- 9.50

-10.48

-11.46

-12.44

-13.44

-14.43

110 (43)

- 1.72

- 2.58

- 3.45

- 4.32

- 5.20

- 6.08

- 6.97

- 7.87

- 8.78

- 9.69

-10.61

120 (49)

+ 1.08

- 0.29

- 0.51

- 1.32

- 2.13

- 2.95

- 3.77

- 4.61

- 5.44

- 6.29

- 7.14

130 (54)

+ 3.59

+ 2.84

+ 2.08

+ 1.32

+ 0.56

- 0.21

- 0.99

- 1.77

- 2.56

- 3.35

- 4.15

140 (60)

+ 5.79

+ 5.08

+ 4.34

+ 3.58

+ 2.82

+ 2.06

+ 1.28

+ 0.50

- 0.28

- 1.08

- 1.88

150 (66)

+ 7.41

+ 6.70

+ 6.00

+ 5.29

+ 4.57

+ 3.84

+ 3.11

+ 2.34

+ 1.57

+ 0.79

0

160 (71)

+ 8.79

+ 8.09

+ 7.38

+ 6.64

+ 5.90

+ 5.15

+ 4.40

+ 3.64

+ 2.87

+ 2.10

+ 1.31

170 (77)

+ 9.77

+ 9.07

+ 8.37

+ 7.65

+ 6.92

+ 6.17

+ 5.42

+ 4.66

+ 3.89

+ 3.11

+ 2.33

180 (82)

+10.55

+ 9.85

+ 9.14

+ 8.43

+ 7.71

+ 6.98

+ 6.24

+ 5.50

+ 4.75

+ 3.99

+ 3.22

190 (88)

+11.23

+10.55

+ 9.86

+ 9.16

+ 8.46

+ 7.75

+ 7.03

+ 6.30

+ 5.57

+ 4.83

+ 4.08

200 (93)

+11.89

+11.22

+10.55

+ 9.86

+ 9.17

+ 8.48

+ 7.78

+ 7.07

+ 6.35

+ 5.62

+ 4.89

210 (99)

+12.52

+11.87

+11.21

+10.54

+ 9.86

+ 9.17

+ 8.47

+ 7.76

+ 7.04

+ 6.31

+ 5.58

220 (104)

+13.08

+12.43

+11.76

+11.10

+10.42

+ 9.74

+ 9.05

+ 8.35

+ 7.64

+ 6.92

+ 6.19

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-15.44

-16.46

-17.46

-18.47

-19.50

-20.52

-21.56

-22.60

-23.65

-24.70

110 (43)

-11.53

-12.45

-13.37

-14.31

-15.24

-16.19

-17.14

-18.10

-19.07

-20.04

120 (49)

- 8.00

- 8.87

- 9.74

-10.61

-11.50

-12.39

-13.28

-14.18

-15.08

-15.99

130 (54)

- 4.95

- 5.76

- 6.57

- 7.42

- 8.29

- 9.17

-10.05

-10.94

-11.84

-12.75

140 (60)

- 2.67

- 3.48

- 4.29

- 5.10

- 5.92

- 6.75

- 7.58

- 8.43

- 9.31

-10.19

150 (66)

- 0.79

- 1.59

- 2.41

- 3.25

- 4.09

- 4.95

- 5.80

- 6.67

- 7.54

- 8.42

160 (71)

+ 0.52

- 0.27

- 1.08

- 1.90

- 2.75

- 3.59

- 4.45

- 5.32

- 6.19

- 7.07

170 (77)

+ 1.54

+ 0.74

- 0.07

- 0.88

- 1.70

- 2.53

- 3.37

- 4.21

- 5.06

- 5.92

180 (82)

+ 2.45

+ 1.67

+ 0.88

+ 0.09

- 0.71

- 1.52

- 2.34

- 3.16

- 3.99

- 4.83

190 (88)

+ 3.32

+ 2.56

+ 1.79

+ 1.01

+ 0.23

- 0.56

- 1.36

- 2.16

- 2.98

- 3.80

200 (93)

+ 4.15

+ 3.40

+ 2.64

+ 1.87

+ 1.09

+ 0.29

- 0.51

- 1.31

- 2.13

- 2.95

210 (99)

+ 4.84

+ 4.09

+ 3.34

+ 2.57

+ 1.80

+ 1.02

+ 0.23

- 0.58

- 1.39

- 2.20

220 (104)

+ 5.45

+ 4.71

+ 3.96

+ 3.20

+ 2.44

+ 1.66

+ 0.88

+ 0.09

- 0.70

- 1.51

NOTE:

Oil MIL-L-7808

Example:

Observed NGG 8600 RPM Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +1.28 psig (8.8 kPa) Corrected Pressure 40 +1.28 = 41.28 psig (284.6 kPa)

7-8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-2. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil 7-9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 7-3. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators Using MIL-L-23699 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 56-68 psig(386-469 kPa). Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

-10.52

-12.01

-13.52

-15.04

-16.58

-18.12

-19.68

-21.25

-22.84

-24.43

-26.04

110 (43)

- 5.20

- 6.60

- 8.03

- 9.49

-10.98

-12.48

-14.00

-15.53

-17.07

-18.59

-20.10

120 (49)

- 0.99

- 2.30

- 3.62

- 4.96

- 6.29

- 7.64

- 9.01

-10.38

-11.77

-13.18

-14.56

130 (54)

+ 3.19

+ 2.02

+ 0.83

- 0.37

- 1.57

- 2.79

- 4.01

- 5.24

- 6.48

- 7.72

- 8.98

140 (60)

+ 7.26

+ 6.16

+ 5.05

+ 3.93

+ 2.80

+ 1.67

+ 0.52

- 0.63

- 1.80

- 2.97

- 4.15

150 (66)

+10.75

+ 9.71

+ 8.66

+ 7.61

+ 6.54

+ 5.47

+ 4.39

+ 3.31

+ 2.22

+ 1.11

0

160 (71)

+13.80

+12.83

+11.84

+10.79

+ 9.73

+ 8.65

+ 7.57

+ 6.48

+ 5.38

+ 4.27

+ 3.15

170 (77)

+15.99

+15.00

+14.01

+13.01

+12.00

+10.99

+ 9.97

+ 8.94

+ 7.87

+ 6.77

+ 5.66

180 (82)

+17.80

+16.77

+15.73

+14.67

+13.62

+12.55

+11.47

+10.38

+ 9.28

+ 8.17

+ 7.05

190 (88)

+18.85

+17.84

+16.83

+15.82

+14.79

+13.74

+12.69

+11.62

+10.55

+ 9.47

+ 8.37

200 (93)

+19.85

+18.87

+17.88

+16.88

+15.88

+14.86

+13.83

+12.79

+11.74

+10.68

+ 9.61

210 (99)

+20.79

+19.83

+18.87

+17.89

+16.91

+15.91

+14.91

+13.89

+12.87

+11.83

+10.79

220 (104)

+21.68

+20.75

+19.80

+18.85

+17.89

+16.91

+15.93

+14.94

+13.93

+12.92

+11.90

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-27.67

-29.30

-30.95

-32.61

-34.28

-35.96

-37.66

-39.37

-41.10

-42.85

110 (43)

-21.62

-23.15

-24.70

-26.25

-27.80

-29.38

-30.97

-32.57

-34.18

-35.80

120 (49)

-15.95

-17.35

-18.73

-20.11

-21.51

-22.93

-24.35

-25.78

-27.22

-28.67

130 (54)

-10.25

-11.52

-12.80

-14.10

-15.40

-16.72

-18.03

-19.36

-20.70

-22.05

140 (60)

- 5.43

- 6.54

- 7.75

- 8.97

-10.19

-11.43

-12.67

-13.92

-15.18

-16.45

150 (66)

- 1.11

- 2.23

- 3.36

- 4.50

- 5.64

- 6.87

- 8.11

- 9.36

-10.62

-11.88

160 (71)

+ 2.02

+ 0.88

- 0.27

- 1.41

- 2.56

- 3.72

- 4.89

- 6.06

- 7.25

- 8.44

170 (77)

+ 4.50

+ 3.33

+ 2.14

+ 0.93

- 0.28

- 1.49

- 2.72

- 3.96

- 5.21

- 6.47

180 (82)

+ 5.92

+ 4.77

+ 3.63

+ 2.46

+ 1.29

+ 0.10

- 1.10

- 2.31

- 3.53

- 4.76

190 (88)

+ 7.27

+ 6.15

+ 5.03

+ 3.89

+ 2.74

+ 1.58

+ 0.42

- 0.76

- 1.95

- 3.15

200 (93)

+ 8.54

+ 7.45

+ 6.34

+ 5.23

+ 4.11

+ 2.98

+ 1.84

+ 0.69

- 0.47

- 1.64

210 (99)

+ 9.73

+ 8.67

+ 7.59

+ 6.51

+ 5.41

+ 4.30

+ 3.19

+ 2.06

+ 0.93

- 0.21

220 (104)

+10.86

+ 9.80

+ 8.73

+ 7.64

+ 6.54

+ 5.43

+ 4.31

+ 3.17

+ 2.03

+ 0.88

NOTE:

Oil MIL-L-23699

Example:

Observed NGG 8700 RPM Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -5.24 psig (36.1 kPa) Corrected Pressure 56 -5.24 = 50.76 psig (349.9 kPa)

7-10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-3. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator Using MIL-L-23699 Oil 7-11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 7-4. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators Using MIL-L-7808 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 47.5-58.5 psig (328-403 kPa). Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

- 4.08

- 5.20

- 6.34

- 7.49

- 8.65

- 9.82

-10.99

-12.18

-13.37

-14.57

-15.78

110 (43)

+ 0.05

- 1.01

- 2.07

- 3.14

- 4.22

- 5.31

- 6.41

- 7.52

- 8.63

- 9.76

-10.89

120 (49)

+ 3.54

+ 2.54

+ 1.54

+ 0.54

- 0.48

- 1.50

- 2.53

- 3.57

- 4.61

- 5.66

- 6.72

130 (54)

+ 6.58

+ 5.59

+ 4.60

+ 3.59

+ 2.57

+ 1.55

+ 0.51

- 0.53

- 1.58

- 2.64

- 3.17

140 (60)

+ 8.65

+ 7.71

+ 6.77

+ 5.82

+ 4.87

+ 3.90

+ 2.88

+ 1.85

+ 0.80

- 0.30

- 1.40

150 (66)

+10.25

+ 9.27

+ 8.27

+ 7.27

+ 6.26

+ 5.25

+ 4.22

+ 3.18

+ 2.13

+ 1.07

0

160 (71)

+11.32

+10.36

+ 9.40

+ 8.42

+ 7.44

+ 6.45

+ 5.44

+ 4.43

+ 3.40

+ 2.37

+ 1.33

170 (77)

+12.33

+11.39

+10.45

+ 9.50

+ 8.54

+ 7.57

+ 6.59

+ 5.60

+ 4.60

+ 3.59

+ 2.58

180 (82)

+13.27

+12.37

+11.45

+10.52

+ 9.59

+ 8.64

+ 7.68

+ 6.72

+ 5.74

+ 4.75

+ 3.76

190 (88)

+14.19

+13.30

+12.40

+11.49

+10.58

+ 9.65

+ 8.72

+ 7.78

+ 6.80

+ 5.83

+ 4.83

200 (93)

+15.04

+14.15

+13.25

+12.34

+11.42

+10.49

+ 9.55

+ 8.60

+ 7.64

+ 6.67

+ 5.69

210 (99)

+15.71

+14.84

+13.95

+13.65

+12.14

+11.21

+10.27

+ 9.33

+ 8.37

+ 7.41

+ 6.43

220 (104)

+16.31

+15.44

+14.56

+13.67

+12.77

+11.86

+10.94

+10.00

+ 9.06

+ 8.11

+ 7.15

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-16.99

-18.22

-19.45

-20.70

-21.95

-23.21

-24.49

-25.76

-27.50

-28.35

110 (43)

-12.03

-13.18

-14.34

-15.51

-16.68

-17.86

-19.05

-20.25

-21.46

-22.67

120 (49)

- 7.78

- 8.89

- 9.93

-11.07

-12.24

-13.41

-14.60

-15.79

-17.00

-18.21

130 (54)

- 4.79

- 5.86

- 6.94

- 8.04

- 9.13

-10.24

-11.35

-12.48

-13.66

-14.85

140 (60)

- 2.52

- 3.65

- 4.78

- 5.94

- 7.09

- 8.25

- 9.41

-10.60

-11.79

-13.00

150 (66)

- 1.09

- 2.17

- 3.28

- 4.40

- 5.52

- 6.65

- 7.79

- 8.94

-10.11

-11.28

160 (71)

+ 0.27

- 0.79

- 1.87

- 2.95

- 4.05

- 5.15

- 6.27

- 7.39

- 8.53

- 9.67

170 (77)

+ 1.55

+ 0.51

- 0.54

- 1.60

- 2.67

- 3.74

- 4.83

- 5.93

- 7.03

- 8.15

180 (82)

+ 2.76

+ 1.74

+ 0.72

- 0.32

- 1.36

- 2.41

- 3.49

- 4.57

- 5.67

- 6.79

190 (88)

+ 3.82

+ 2.80

+ 1.78

+ 0.74

- 0.31

- 1.37

- 2.44

- 3.52

- 4.61

- 5.71

200 (93)

+ 4.69

+ 3.68

+ 2.65

+ 1.62

+ 0.58

- 0.48

- 1.54

- 2.62

- 3.70

- 4.80

210 (99)

+ 5.44

+ 4.44

+ 3.44

+ 2.42

+ 1.39

+ 0.35

- 0.69

- 1.75

- 2.82

- 3.90

220 (104)

+ 6.18

+ 5.20

+ 4.21

+ 3.20

+ 2.19

+ 1.17

+ 0.14

- 0.90

- 1.95

- 3.02

NOTE:

Oil MIL-L-7808

Example:

Observed NGG 8600 RPM Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +2.88 psig (19.9 kPa) Corrected Pressure 40 +2.88 = 42.88 psig (295.6 kPa)

7-12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-4. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator Using MIL-L-7808 Oil 7-13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 7-5. LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 1 of 4)

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-5.LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 2 of 4) 7-15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 7-5. LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 3 of 4) 7-16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 7-5. LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 4 of 4)

7-17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

7-3.4.5 Adjustment of Engine High Pressure Recoup Cavity Pressure Within Preferred Operating Range NOTE High pressure recoup should be checked at initial startup and periodically thereafter. Refer to Chapter 11, Table 11-1, and WP 417 00. Maintenance of engine high pressure (HP) recoup cavity pressure in the preferred operating range is required to ensure No. 4B bearing life. During initial buildup of engine, HP recoup cavity pressure was adjusted into the preferred operating range with the proper size metering spacers. Periodic plotting of the HP recoup cavity pressure is required in service, because seal leakage can change with operation of the engine and may cause HP recoup cavity pressure to fall outside the preferred operating range. Refer to WP 417 00 for procedure. 7-3.4.6

Adjustment of Power Turbine (PT) Thrust Balance Cavity Pressure Within Preferred Operating Range (6-Stage PT Applications Only)

Periodic plotting of the PT thrust balance cavity pressure is required in service because seal leakage can change with the operation of the engine. This may cause PT thrust balance cavity pressure to fall outside the preferred operating range. Refer to Volume II, WP 431 00, for procedure. 7-3.5

The engine and package should undergo a thorough prestart inspection during installation or after maintenance to ensure a troublefree transition from installation to full operation. This inspection will help to detect potential installation problems. The following inspections should be performed during installation of the engine in the enclosure: a.

Inspect the enclosure per the packager's instructions.

b.

Perform an external inspection. Ensure that all connections are tight and that no binding or chafing is evident on flexible electrical cables, hoses, or tubes.

c

Bonding straps are in place and secure.

d.

Inspect the engine inlet area. Thoroughly inspect the inlet plenum for dirt and foreign objects. Clean, vacuum, and/or wash the area as necessary.

e.

Inspect the exhaust system for foreign objects.

f.

Ensure that the lube system is properly serviced.

g.

Inspect for leaks in fuel and lube oil lines.

h.

Ensure CRF leakage ports, struts 7 and 10, are open (not capped)

i.

Ensure T5.4 thermocouple system functions properly.

j.

Ensure steam manifolds are aligned (if required).

NOTE PT thrust balance cavity pressure should be checked at initial startup and periodically thereafter. Refer to Chapter 11, Table 11-1, and Volume II, WP 431 00. Maintenance of PT thrust balance cavity pressure in the preferred operating range is required to ensure No. 7B bearing life. During initial buildup of engine, PT thrust balance cavity pressure was adjusted into the preferred operating range with the proper size orifice plate.

Initial Prestart Inspections

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

k.

Ensure steam HP recoup system is installed (if required).

l.

Ensure fire/alarm system is functional.

7-3.6

GEK 105054 Volume I

Initial Operational Checkout

1.

With ignition leads disconnected and fuel shutoff valves closed, make automatic start of GG per packager’s manual.

2.

GG should go through normal start cycle and then abort because of lack of flame/ignition.

CAUTION IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

e.

Perform prestart as follows:

The initial startup procedures described in this section should be followed after any engine installation, GG replacement, or major system or engine maintenance. The engine should be operated at various speed/load conditions in order to establish baseline performance for the specific installation. Refer to paragraph 7-4.4.1c. a. b. c.

Perform initial prestart inspection, per paragraph 7-3.5.

Motor the engine for 2 minutes per the packager's instructions and per Motoring in paragraph 7-4.3. During motoring, check for the following: Oil pressure indication

•

Lube oil leaks

•

Unusual noise during coastdown Perform false start as follows:

With ignition system disabled, but with fuel shutoff valve open and governing system operating, make automatic start of GG per packager’s manual.

2.

GG should accelerate to applicable light-off speed. Fuel valve should open and fuel manifold pressure should be verified. Start will then abort because of lack of flame/ ignition.

3.

Allow GG to coast to stop; then motor it to purge any remaining fuel from GG or drain liquid fuel from manifolds (if liquid fuel was used). Continue to motor for a minimum 60 seconds to purge fuel from GG. Consult packager’s manual for necessary prestart purge time.

Perform the following ignition system functional check:

Perform normal prestart checks, per paragraph 7-4.2.

•

d.

f.

1.

WARNING

•

IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE.

•

ENSURE FUEL VALVES ARE CLOSED THROUGHOUT THIS PROCEDURE. 7-19

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 1.

2.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

To clear combustor of any residual fuel, motor GG for 1.0 minute; allow GG to coast down. If the package is equipped with the optional second ignition exciter, disconnect one ignition exciter input lead at exciter. Temporarily secure input lead away from the exciter.

3.

Turn on electrical power to ignition system. An audible report (approximately two sparks per second) should be heard when spark igniter fires.

4.

Turn off electrical power to ignition system. Reconnect input lead to exciter.

5.

If equipped, repeat steps 2, 3, and 4, disconnecting the input lead to the second exciter.

6.

•

Check all parameters and verify that values are within normal range per Table 7-5

•

Observe and record all results

•

Correct discrepancies prior to load application

i.

Operation to maximum power. 1.

Slowly increase control setting (refer to packager’s manual) to increase gas generator speed (NGG). After each 500 RPM increase, log all instrument readings, paying particular attention to variable stator vane (VSV) position and vibration. If variable stator system is not within limits, inspect it per WP 419 00. If vibrations are not within limits, consult local General Electric Company representative.

2.

Operate GG up to rated power. The GG’s output will normally be limited by compressor discharge pressure (PS3) or on extremely cold days corrected core speed. Hold at this power setting until engine stabilizes.

If an audible report is not heard on first or second igniters, check out system to isolate problem, and take appropriate corrective action. WARNING

NOTE

WHEN WORKING INSIDE OR NEAR THE ENGINE ENCLOSURE DURING OPERATION, OBSERVE THE SAFETY PRECAUTIONS DESCRIBED IN PARAGRAPH 7-2.

Normal operating parameter ranges and limits are shown in Tables 7-5 and 7-6. Refer to Tables 7-7 and 7-8, and the appropriate Addendum in Volume 1 when operating with NOx Suppression.

g.

Perform verification test per paragraph 7-3.7.

h.

Make a normal start (paragraph 7-4.4, Starting and Operation) and set power at idle. When the engine is stabilized at idle, do the following:

•

Check engine and supply systems for leaks

•

Check for loose parts, tubing, cabling, etc.

3.

Compare recorded readings to typical values in Table 7-5 and troubleshoot as required.

4.

Log all instrument readings once they stabilize.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

7-3.7

Verification Test

If no verification test is specified by the packager, the verification test described below should be performed after the initial operational checkout (paragraph 7-4.6) has been completed. Record any abnormal condition and perform any needed corrective action. a.

GEK 105054 Volume I

Verify all service systems (electrical, air, fuel, lube oil, fire control, water, indicators, and controls) are checked out and ready for operation.

NOTE Optimization of control schedules via combustor mapping should be accomplished prior to operation at full power. e.

Restart the engine and slowly advance to full power. If the accel follows a cold start, it should be at a rate not to exceed zero to maximum load in less than 5 minutes. A ramped (constant rate) load increase should be maintained during the accel.

f.

Stabilize at full power for 3 minutes, then observe and record the data specified in Table 7-5, Typical Operating Levels.

b.

Make a start (paragraph 7-4.4, Starting and Operation).

c.

Hold at idle for 5 minutes minimum.

g.

Reduce power to idle.

d.

Perform PT overspeed shutdown test on each channel, with the PT unloaded, by slowly increasing power turbine speed (NPT) until automatic shutdown occurs. Shutdown should occur at appropriate trip speed for model. If automatic shutdown does not occur, shutdown manually and check speed indication and automatic shutdown systems.

h.

Perform a normal shutdown, (paragraph 7-4.5.1, Normal Shutdown).

i.

Inspect for leakage and loose parts and take any corrective action required.

j.

Check lube and scavenge pump screens for evidence of contamination.

7-21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7-5. Typical Operating Levels

Parameter T2, °F (°C) (Inlet temperature) P2, psia (kPa absolute) (Inlet pressure) NGG, rpm (Gas generator speed) PS3, psia (kPa absolute) CDP T3, °F (°C) (Compressor discharge temperature) WF36, lb/hr (kg/hr) @ 19,000 BTU/lb (10,555 kcal/kg) (Gas fuel flow) WF36, lb/hr (kg/hr) @ 18,400 BTU/lb (10,555 kcal/kg) PT5.4, psia (kPa absolute) (Power Turbine [PT] inlet pressure) T5.4, °F (°C) (see Figure 7-6) (PT inlet temperature) PT speed for 60 Hz (rpm) PT speed for 50 Hz (rpm) VSV position, degrees Lube supply pressure, psig (kPa gage) Lube supply temperature, °F (°C) Lube scavenge pressure, psig (kPa gage) Lube scavenge temperature (A/TGB-sump), °F (°C) (Note 8)

Max Operating Limit (Note 1) N/A

IDLE 40 to 70 (4.4 to 21.1) 14.5 - 14.8 (99.97 - 102.04) 5900 - 6100 (Note 2) 40 - 55 (275.8 - 379.2) 285 to 365 (140.6 to 184.9)

Max Power 40 to 70 (4.4 to 21.1) 14.5 - 14.8 (99.97 - 102.04) 9150 - 9600

10,050 (Note 3)

280 - 320 (1930.5 - 2206.3) 835 to 890 (446.1 to 476.6)

300-335 (Note 9) (2068.4 - 2309.7) 935 (501.6)

1200 - 1500 (544.3 - 680.4)

11400 - 14300 (5170.9 - 6485.4)

N/A

1200 - 1500 (544.3 - 680.4) 17 - 19 (117.2 - 131.0) 1150 to 1350 (621.1 to 732.2)

30 to 34 8 - 15 (Note 5) (55.2 - 103.4) 140 to 160 (59.9 to 71.1) See appropriate packager manual 10 to 30 (5.5 to 16.6)

N/A

N/A 60 - 70 (413.7 - 482.6)

N/A

1455 to 1520 (790.6 to 826.7) 0 - 3600 0 - 3000 4 to 8 20 - 60 (Note 5) 137.9 - 413.7) 140 to 160 (59.9 to 71.1) 5 - 100 (34.4 - 689.4) 30 to 65 (16.6 to 36.1)

1566 (Note 4) (852.2)

N/A 8 min (Note 6) (55.1 min) 200 (Note 7) (93.3) 110 (Note 7) (758.4) 340 (171.1)

7-22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 7-5. Typical Operating Levels - (Cont.)

Parameter Lube scavenge temperature (B-sump), °F (°C) (Note 8) Lube scavenge temperature (C-sump), °F (°C) (Note 8) Lube scavenge temperature (D-sump), °F (°C) (Note 8) Lube scavenge temperature (AGB), °F (°C) (Note 8) Gas manifold pressure, psig (kPa gage) Natural gas fuel manifold pressure, psig (kPa gage) (With or without water/steam injection for NOx suppression) Natural gas fuel manifold temperature, °F (°C) (Natural gas models only) Starter supply pressure (optional air/ gas starters only) Liquid fuel manifold pressure, psig (kPa gage) (Liquid fuel only models only) Liquid fuel manifold pressure, psig (kPa gage) (Liquid fuel and dual fuel, water injected models only) Liquid fuel manifold temperature, °F (°C) (Liquid fuel models)

IDLE 10 to 15 (5.5 to 8.3) 10 to 40 (5.5 to 22.2) 10 to 40 (5.5 to 22.2) -10 to 30 (-5.5 to 16.6) 40 - 50 (275.8 - 344.7)

Recoup pressure, psig (kPa gage)

See Chapter 11 NOTE 1:

Max Power 70 to 120 (38.8 to 66.6) 60 to 110 (33.3 to 61.1) 20 to 80 (11.1 to 44.4) 20 to 50 (11.1 to 27.7) 335 - 385 (2209.7 - 2654.4) 20 - 390 (137.9 - 2689.0)

Max Operating Limit (Note 1) 340 (171.1) 340 (171.1) 340 (171.1) 340 (171.1) N/A

-65 to 150 (-53.8 to 65.5) 35 - 40 psig (241.3 - 275.7 kPa) 150 - 900 psig (1034.2 - 6205.2) 0 - 395 (0 - 2723.4) 20° (above wax point of fuel) to 150 ° (11 to 65.5) See Chapter 11

See Chapter 11

Unless otherwise noted, limits are shutdown limits. Reference Chapter 9, Engine Troubleshooting for complete electronic control alarm and shutdown limits. NOTE 2: For T2 temperatures between -30°F (-34.4°C) and 130°F (54.4°C).

7-23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7-5. Typical Operating Levels - (Cont.)

Parameter

IDLE

Max Power

Max Operating Limit (Note 1)

NOTE 3: NGG limit at T2=59°F (14.9°C); otherwise limited to 9,563 - 10,100 rpm over T2 from 10° to 120°F (-12.2° to 48.8°C) range. Shutdown limit 10,200 rpm. NOTE 4: Shutdown limit 1,600°F (871.1°C). NOTE 5: Correct and establish normal lube pressure range per Chapter 5. NOTE 6: At NGG > 4,500 rpm. NOTE 7: Alarm only. NOTE 8: Increase in scavenge temperature over lube supply temperature. Alarm limit 300°F (148.9°C). NOTE 9: Shutdown limit is 375 psia (2,585.5 kPa absolute). Table 7-6. Limits and Operating Requirements Event/Item

Max Limits/Requirements

Max Time Allowed for Ignition

t > 10 seconds after fuel/ignition application (gas) t > 20 seconds after fuel/ignition application (liquid)

Max Time to Reach Starter Cutout

NGG > 4,500 rpm at t _ 90 seconds

Max Time to Reach Idle

NGG > 6,050 rpm at t _ 120 seconds

HP Rotor Vibrations

4 mils or 1.75 in/sec at > 125 Hz and 1.5 in/sec < 125 Hz

Fuel Supply Temperature (Gas)

< Tsv +20°F (11°C) min; > 300°F (148.8°C)

PT Rotor Vibrations

7 mils or 1.25 in/sec at 45 Hz and 0.75 in/sec < 45 Hz

7-24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 7-7. Gas Turbine/Gas Generator Steam Limits (Steam Only Models)

Max Operating Limit Parameter Steam Pressure at Manifold Inlet Steam Supply Temperature at manifold inlet Steam Scheduling Relative to Fuel flow During Transients Steam Metering Valve Closing Time Steam Shutoff Valve Closing Time (GT only)

Min Operating Limit

Normal Operating Limit Remarks 400 psig (2,757.9 kPa)

960°F (515.5°C)

50°F (9.9°C) of Superheat See Appendix A6 < 100 ms < 1.0 sec NOTE 1:

The LM2500+ SAC steam injected GT does not require any particular minimum steam flow through the fuel nozzle steam manifold, however considerations must be given to the system external to the engine with respect to line lengths, volumes, pipe lagging, cooling air flow over the lines, etc., to prevent condensate from developing due to an inadequate superheat and/or insufficient flow through the external pipes and components. NOTE 2: This pressure is for sea level operation and must be corrected for altitude for each engine installation.

Table 7-8. Gas Turbine/Gas Generator Water Injection Limits for NOx Suppression

Parameter Water Pressure at Manifold Inlet Water Supply Temperature

Max Operating Limit 400 psig (2,757.9 kPa) 180°F (82.2°C)

Min Operating Limit

Normal Operating Limit Remarks

See Note 1 NOTE

Manifold shall be free of pressure pulsations in the 0 to 100 Hz range. The water must be controlled in a manner to prevent any sudden pressure spikes which could momentarily displace fuel.

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GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 7-6. Transient Temperature Limits (Typical)

7-26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

7-4

ENGINE OPERATION

Operational procedures are also presented in this section. Prior to operation of the engine, the site operators should be thoroughly schooled in both normal and abnormal (emergency) operations and the control system action/reaction to these conditions. This section offers guidelines for tracking engine operation times and maintenance actions, a thorough history of the GT’s performance will aid in further operations and maintenance decisions. 7-4.1

Component Life/Repair Intervals

Safe operation of the LM2500+ SAC is dependent on properly scheduled maintenance, repairs, and component replacement. In order to properly track these conditions, packagersupplied time and event counters provide data for the parameters. Tracking instructions are TBD. 7-4.2

Prestart Checks

Consult the packager's manual for mandatory prestart procedures to ensure that packagerfurnished systems are activated and operational. Prior to any motoring or start sequence, GE suggests the following checks as a minimum:

•

All maintenance requirements or discrepancies are cleared and signed off

•

Ensure that the inlet and enclosure have been inspected and cleaned in accordance with instructions in the packager's manual

GEK 105054 Volume I

•

Fuel shutoff valves are closed

•

Ignition system is off

•

Lube tank level is full

•

Lube supply valves are open

•

Lube oil temperature is above 20°F (-6.7°C) for MIL-L-23699 or above -20°F (-28.9°C) for MIL-L-7808

•

T5.4 less than 400°F (204.4°C)

•

All switches and interlocks set for proper sequence to allow motoring

•

Fuel metering valve at start position

•

VSVs at scheduled position

•

Gas vent valves set for gas startup

•

Liquid drain valves closed at liquid startup

•

Fire alarm/extinguisher system activated

•

Required checks and inspections for GT electronic control have been performed in accordance with packager’s manual

Although not necessarily required as part of normal starting procedures, motoring is frequently used following maintenance to check the engine prior to making a start. Motoring is performed with the fuel shutoff valves closed.

7-27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 7-4.3

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Motoring Procedures CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

c.

7-4.4

FOR MAXIMUM SAFETY, OPERATING PERSONNEL SHOULD REMAIN CLEAR OF THE PLANE OF THE GG STARTER WHEN STARTING THE UNIT AND SHOULD REMAIN CLEAR OF THE GG PLANE DURING OPERATION, EXERCISING THE SAME CARE REQUIRED IN THE VICINITY OF ANY HIGH-SPEED ROTATING EQUIPMENT. ENTERING THE ENCLOSURE DURING OPERATION ABOVE IDLE SPEED IS NOT RECOMMENDED. PROLONGED EXPOSURE TO THE GG SOUND LEVELS MAY CAUSE HEARING LOSS. CAUTION

After all preliminary checks have been completed and lines flushed, GG can be motored as follows:

b.

•

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

•

IT IS CRITICAL THAT THE COLD START PROCEDURE BE FOLLOWED; OTHERWISE, MAJOR ENGINE DAMAGE CAN RESULT.

Make ignition and fuel-gas supply systems inoperative as follows: Disconnect power supply to ignition unit(s).

(2)

Close manual shutoff valve(s) to fuel skids.

Motor GG until gas generator speed (NGG) stabilizes and check for oil pressure. If there is no indication of oil pressure, stop motoring. Loosen oil fittings at lube pump inlet to bleed air from system and ensure pump is primed. Starter should motor GG to minimum of 2,200 rpm at full supply pressure to starter.

Normal Starting Sequence WARNING

Be certain that checklists have been established for packager-furnished equipment. Consult the packager's manual for mandatory prestart procedures and make certain that the packager-furnished lube supply subsystem is activated and operational prior to any motoring or start sequence.

(1)

Starting and Operation

7-4.4.1

NOTE

a.

Repeat motoring and bleeding procedure until an indication of oil pressure appears.

a.

Ensure that all prestart checks have been completed.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

CAUTION MODELS LM2500-PK-MD AND LM2500-PK-MDW ARE DESIGNED TO OPERATE ON 100 PERCENT LIQUID FUEL, 100 PERCENT NATURAL GAS OR A COMBINATION OF THE TWO. THE GAS TURBINES CAN BE STARTED ON EITHER NATURAL GAS OR LIQUID FUEL BUT NOT ON A COMBINATION OF THE TWO. WHEN OPERATING ON BOTH FUELS, NEITHER THE NATURAL GAS OR LIQUID FUEL FLOW SHOULD BE LESS THAN THE IDLE FUEL FLOW; I.E. IF OPERATING ON BOTH FUELS, THE MINIMUM FLOW TO THE GAS TURBINE WILL BE LIQUID FUEL IDLE FLOW PLUS NATURAL GAS IDLE FLOW.

GEK 105054 Volume I

•

Lightoff should occur in approximately 5 seconds

•

The PT rotor will start to rotate before the GG reaches idle speed

•

The engine will accelerate to idle (starterassisted to 4,500 rpm, where starter-cutout occurs)

•

Finish 5 minute warmup prior to loading

•

Check parameters per Table 7-5

•

Accelerate to desired load. Maintain a constant rate of load increase during acceleration. Stepped acceleration should be avoided

c.

Check and record the levels of the operating parameters designated in Tables 7-5 and 7-6. If all parameters shown in Tables 7-5 and 7-6 are normal, engine operation may continue. If engine parameters are outside the normal operating limits shown in Tables 7-5 and 7-6, troubleshoot and correct the problem per Chapter 9 before continuing.

NOTE

b.

•

A start may be aborted at any time by closing the fuel valve, allowing the gas generator to motor for 60 seconds, then closing the starter shutoff valve

•

When switching from liquid fuel burning to 100% natural gas burning, it is necessary to purge and cool the liquid portion of the fuel nozzles. Either natural gas or compressed air may be used to purge the fuel nozzles. Refer the packager’s manual. Engage the starter or initiate the start sequence. The following should occur:

•

The engine will begin to rotate and accelerate to greater than 1,700 rpm and stabilize

•

The ignition will be energized 2 minutes after reaching 1,700 rpm

•

The fuel shutoff valves will open

7-4.4.2

Hot Starts

a.

Starts indicating a T5.4 value in excess of 1,300°F (704.4°C) are considered to be hot starts. Normal starts are 1,000 to 1,200°F (537.7 to 648.8°C).

b.

Hot starts are typically the result of insufficient starter power, excess starting fuel flow, excessively high acceleration fuel flow rate, or open VSVs.

c.

If a hot start occurs, the startup procedure should not be repeated without investigating the cause of the hot start. For troubleshooting procedures, refer to Chapter 9

7-29 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 7-4.5

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

•

Shutdown NOTE

The information presented herein describes a typical sequence of events. However, for specific control sequencing modes and site operation information, see the packager's manual. The following types of engine shutdowns may occur: Normal shutdown: engine is taken off-line for a specific reason, annunciated fault, or other indication of problem which operator interprets as a reason for taking the engine offline or for reasons not necessarily related to the engine

Shutdown procedures are dependant on application. See packager’s manual. Under normal operating conditions, the engine is shut down in the sequence described below. a.

Normal Shutdown

•

HP rotor speed decreases to approximately 7,600 rpm (sync idle/min-load) over a 2 - 3 minute period

•

T5.4 decreases

•

Disconnection of generator from grid is initiated (where applicable)

CAUTION

•

THERMAL SEIZURE OF THE PT ROTOR CAN OCCUR WHEN A HOT GT IS SHUT DOWN AND IS MOST LIKELY TO OCCUR WITHIN 30 TO 40 MINUTES FOLLOWING GT OPERATION. THERMAL SEIZURE IS THE CONDITION WHERE THE PT ROTOR IS PREVENTED FROM ROTATING BY HARD CONTACT BETWEEN LPT BLADES AND SHROUDS, INTERSTAGE SEALS AND OTHER INTERNAL INTERFERENCE. THIS CONDITION IS THE RESULT OF UNEQUAL COOLING RATES OF THE VARIOUS PT COMPONENTS. THE POSSIBILITY OF THERMAL SEIZURES CAN BE REDUCED BY OPERATING THE GT AT IDLE POWER FOR AT LEAST 5 MINUTES PRIOR TO SHUTDOWN TO ACHIEVE PROPER COOLING OF THE PT.

Typical shutdown on electrical generator application: Power is retarded to minimum load (idle) or the control sequencer is activated to accomplish the shutdown. The following should occur:

Emergency shutdown: engine is taken offline by the operator or the control system to prevent damage or injury to equipment or personnel due to an engine or system fault. 7-4.5.1

FOR MODELS OPERATING ON 100 PERCENT LIQUID OR A RATIO OF LIQUID AND NATURAL GAS, IT IS NECESSARY TO DRAIN THE LIQUID FUEL MANIFOLD WHEN THE GAS TURBINE IS SHUT DOWN. THE MAXIMUM TEMPERATURE OF THE FUEL WILL BE 200°F (93.3°C). REFER TO PACKAGER’S MANUAL FOR PROCEDURE.

NOTE After shutdown, natural circulation of air through the engine must not be interrupted.

•

The engine should then decelerate to idle speed, approximately 6,000 rpm, where it should be allowed to cool for 5 minutes. After 5 minutes, the fuel shutoff valves should be closed and the drain valves opened.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

b.

Typical shutdown on pumping application: Power is retarded to minimum load (idle) or the control sequencer is activated to accomplish the shutdown. The following should occur:

•

HP rotor speed decreases to approximately minimum load over a 2 - 3 minute period

•

T5.4 decreases

•

The engine should then decelerate to idle speed, approximately 6,000 rpm, where it should be allowed to cool for 5 minutes. After 5 minutes, the fuel shutoff valves should be closed and the drain valves opened.

7-4.5.2

GEK 105054 Volume I

a.

The fuel shutoff valves and metering valves are closed.

b.

Underspeed and oil pressure alarms are bypassed.

c.

Vent valves/drain valves are opened per control sequencing CAUTION

•

IF THE STEAM AND FUEL VALVES HAVE BEEN SHUT OFF SIMULTANEOUSLY DUE TO AN EMERGENCY CONDITION, SEQUENCING THE NORMALLY CLOSED DRAIN VALVE TO OPEN DURING SPEED ROLLBACK (PREFERABLY IN THE SUB-IDLE REGION) MUST BE ONE SUCH THAT A NATURAL PURGING OF THE MANIFOLD IS ACCOMPLISHED.

•

ASSURE FREEDOM OF ROTATION OF GAS TURBINE AFTER EMERGENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TURBINE ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 - 4 HOURS. CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR BY HAND.

Emergency Shutdown

In an emergency, the engine can be shut down from any power setting. This action can be initiated by the operator or by the packager-supplied control system. An emergency shutdown automatically initiates the following actions: NOTE

•

If emergency shutdown must be initiated while operating an engine equipped with optional NOx suppression on-line, the water and fuel valve can be shut off simultaneously. Action must be taken to purge the water from the fuel manifold at the earliest opportunity and prior to the next startup.

•

If emergency shutdown must be initiated while operating an engine equipped with steam or water injection for NOx suppression, steam/water metering valves and fuel shutoff valve must be closed rapidly. Failure to do so can result in high water/steam to fuel ratio in the combustor resulting in flameout.

Table 7-9 outlines the protection functions that require root cause resolution prior to engine motoring.

7-31 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 7-9. Protective Function Causes Requiring Resolution Prior to Restart or Motoring Protective Function Excessive vibration alarm/shutdown Fire system shutdown and/or Halon release GT lube oil supply pressure low alarm/shutdown Lube scavenge alarm/shutdown Overspeed alarm/shutdown Lube filter pressure drop alarm/shutdown Enclosure high combustible gas level shutdown Lube scavenge pressure alarm Chip detector alarm Starter system failure Fail to crank indication Negative rate of change of PS3 (dPS3/dT) shutdown (stall indication)

7-4.5.3

Post-Shutdown Fire

During a normal shutdown, GG T5.4 should decrease following closure of the fuel shutoff valves. If T5.4 shows temperatures increasing after closure of fuel shutoff valves, combustion is still continuing. (Slight temperature increase after rotation stops is normal.) Ensure fuel is shut off, and motor the GG (paragraph 7-4.3). This will blow out the fire. As soon as temperature decreases to normal, discontinue motor. If condition persists refer to Chapter 9, Trouble-shooting. 7-4.6

b.

Motoring - Air or natural gas 5 minutes on, 2 minutes off, 5 minutes on, 18 minutes off for any number of cycles or 10 minutes on, 20 minutes off for any number of cycles. (For 10 minutes of motoring, maximum starter air inlet temperature is 200°F [93.3°C].)

c.

There is no duty cycle limit on the hydraulic starter as long as oil temperature is maintained below 140°F (59.9°C).

Starter Duty Cycle - Air, Natural Gas, or Hydraulic NOTE

Starter duty cycle applies only to GE supplied starters. a.

Starting - Air or natural gas 45 seconds on, 2 minutes off for any number of cycles or 2 minutes on, 5 minutes off, 2 minutes on, 21 minutes off for any number of cycles.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

7-4.7

Restart CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION HAS BEEN MADE. DO NOT RESTART ENGINE UNTIL CAUSES FOR ANY EMERGENCY SHUTDOWNS OR ABORTED OPERATIONS ARE THOROUGHLY INVESTIGATED AND CORRECTED. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN DAMAGE AND ULTIMATE FAILURE. This section addresses requirements for restarts after operation at power. Restarts may be initiated at any time if the prior shutdown sequence was normal. Restarts following an emergency shutdown or trip from operation at power may be restricted, depending on cause. 7-4.7.1

Hot Restarts

A restart following an emergency shutdown or trip from a power level where T5.4 is higher than 1,150°F (621.1°C) is considered a hot restart sequence and should not be attempted until the fault or circumstance triggering the shutdown is resolved. NOTE Conditions may not allow restarting or motoring in some situations, depending on the cause of the emergency shutdown or the status of the starting system. Reasons for not restarting or motoring the GT following an emergency shutdown are listed in Table 7-9. If the fault causing the emergency shutdown is fully understood, resolved, and cleared, and it has been verified that no damage to the engine has occurred, a restart or motoring sequence can be initiated, if the 10-minute limit has not been exceeded.

GEK 105054 Volume I

It is critical that the hot restart procedure follows a specific sequence to avoid major engine damage. The basic objective is to cool the high pressure turbine rotor (HPTR) and high pressure compressor rotor (HPCR) so blade tips maintain clearance with the more rapidly cooling cases. The restart procedure following a trip from power or an emergency shutdown (T5.4 greater than 1,150°F (621.1°C)) is as follows: An emergency shutdown must be followed by a restart or motoring cycle, if possible, to commence no more than 10 minutes after gas turbine high pressure (HP) rotor speed decreases below 300 rpm per paragraph 7-4.7.1.1. Conditions may not allow restarting or motoring in some situations, depending on the cause of the emergency shutdown or the status of the starting system. Reasons for not restarting or motoring the gas turbine following an emergency shutdown are listed in Table 7-9. If restart or motoring cannot be accomplished within 10 minutes, a mandatory lockout of 4 hours is enacted by the control system to allow sufficient component cooling to prevent possible damage to the engine per paragraph 7-4.7.1.2. 7-4.7.1.1 Restarts Within 10 Minutes After Shutdown a.

If circumstances permit the shutdown problem to be cleared within 10 minutes or less, and the HP rotor speed is less than 300 rpm, the restart procedure is as follows: (1)

Start the restart timer and initiate a manual restart purge. Reset all other timers as required.

(2)

Energize the starter to crank the HP rotor to a speed not to exceed 2,400 rpm for a minimum of 5 minutes. If the HP rotor rotates freely, make a normal start.

7-33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I (3)

(4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

If circumstances allow the HP rotor to be cranked within 10 minutes after shutdown, a manual purge, if available, will enable a restart purge cycle to be initiated. The restart purge cycle motors the engine HP rotor to prevent thermal bowing of the HP rotor.

a.

The GG may windmill for 2 weeks in duration at speeds below 100 rpm, provided each period is preceded by normal engine operation.

b.

The GG may windmill for periods up to 5 minutes at speeds between 100 rpm and 1,000 rpm, provided each period is preceded by normal engine operation.

By selecting the restart purge option, the operator preserves capability to restart the engine any time after the fault or system problem has been cleared.

7-4.7.1.2 Restart More Than 10 Minutes After Shutdown CAUTION BYPASSING THIS LOGIC AND CRANKING THE HP ROTOR MAY RESULT IN SEVERE HP COMPRESSOR RUBS AND MAY DAMAGE THE COMPRESSOR BLADES AND VANES. If it is not possible, or desirable, to initiate the restart purge cycle or a cool-down motoring cycle within 10 minutes after the HP rotor has coasted to below 300 rpm, the control system will then lock out any further attempts to restart or motor the engine for a period of 4 hours.

NOTE Adequate cooling of the oil must be provided at the higher free rotational speeds. Extended windmilling of the GG outside of the envelope described above may be carried out, but this requires additional equipment and protection. Contact GE Marine and Industrial Engine, Customer Service and Product Support, Cincinnati, Ohio 45215, for assistance. 7-4.9

Records and Running Logs

A log should be kept of all engine operation and/or running time. It is recommended that, as a suggested minimum, site operators should record the following:

•

Time of all starts and shutdowns

•

Total time for engine and site

•

After 4 hours, a normal start sequence may be initiated.

Reading of all engine instrument recordings, taken twice daily at the set-load point

•

All changes of engine speed and load

7-4.8

•

Brief statement of action taken in response to alarms or emergencies

•

Any system modifications, adjustments, or parts removal/replacement

•

Preventive or corrective maintenance activity

•

Installation/removal dates and operating hours for any spare or lease pool engine

Windmilling

Windmilling is generally caused by air forced through the inlet, causing the rotors to turn. Windmilling also occurs during shutdown as the kinetic energy of the rotor is dissipated by the pumping and rolling-element friction. The duration of GG windmilling is limited by the lubrication of its rotor bearings. The following defines these limits:

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 8 Abnormal Operation 8-1

PURPOSE AND SCOPE

8-3.1

Alarms

This chapter covers abnormal operating conditions and procedures and control-provided automatic protective features. It provides definitions, descriptions, and operator actions required for abnormal conditions resulting in alarms or protective action. It also covers other conditions that do not trigger alarms or protective action, but which require special action by the operator.

Alarms are used to alert the operator to a condition that requires operator intervention. Alarms indicate that a condition has been reached that may lead to the initiation of a protective action, if not corrected immediately. Refer to the Troubleshooting Reference Table in Chapter 9 for the problem events and system conditions that trigger alarms and protective functions.

8-2

8-3.2

GENERAL DEFINITIONS

Abnormal operation is defined as any type of LM2500+ SAC operating condition that:

•

Deviates from normal operating limits.

•

Causes an alarm or other protective action to be initiated.

A protective action is defined as any action initiated automatically by the packager's control in order to:

•

Prevent damage to the LM2500+ SAC engine or installation.

•

Prevent injury to personnel.

8-3

CONTROL ACTIONS

The following are three levels of protection initiated by the LM2500+ SAC packagersupplied control system when abnormal conditions are sensed:

•

Alarms (alarm-only conditions)

•

Power cutbacks

•

Shutdowns

Power Cutback

There is only one power cutback function in the control. It initiates an alarm and a slow deceleration to minimum load (min-load). A slow deceleration to min-load is a controlled rate that allows all engine schedules and engine cooling to be maintained. Rather than decelerate all the way to idle, the engine decelerates to the min-load point. This allows the condition to be investigated without requiring a shutdown. There is no time limitation for remaining at min-load, unless the condition requiring this deceleration still persists, in which case, a normal shutdown sequence is initiated. 8-3.3

Shutdowns

There are five shutdown functions in the controls as follows:

•

Shutdown (gas turbine [GT] motoring allowed)

•

Emergency shutdown (GT motoring not allowed)

•

Step deceleration to idle/shutdown

•

Slow deceleration to idle/shutdown

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8-1

GEK 105054 Volume I

•

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Abort start/shutdown

These functions all initiate an alarm and a shutdown, but vary in their shutdown sequence. 8-3.3.1 Normal Shutdown A control initiated shutdown is a controlled deceleration to idle, a 5 minute stabilization period, a shutoff of the fuel valves, and opening of drain or vent valves. 8-3.3.2

Emergency Shutdown

A control initiated emergency shutdown occurs when the engine must be shut down immediately in order to prevent severe damage to the engine or installation. When an emergency shutdown occurs, the control initiates the following events: a.

The fuel shutoff valves and metering valve are closed.

b.

Underspeed and oil pressure alarms are bypassed.

c.

Drain and vent valves are opened per control sequencing.

d.

Alarms, interlocks, sequence timers, and operating timers are reset. NOTE The emergency shutdown will not allow reset until gas generator speed (NGG) is less than 400 rpm.

Table 7-3 in Chapter 7 outlines the protection functions that require root cause resolution prior to engine motoring.

8-3.3.3 Step Deceleration to Idle/Shutdown A step deceleration to idle is an immediate rapid (max deceleration rate) deceleration to idle, followed by a 10 second pause, and then by a shutdown. A step deceleration provides a more controlled and orderly way of shutting down the engine than does an immediate shutdown at power. The 10 second pause at idle, allows various scheduled engine systems, such as variable stator vanes, to reach a stabilized condition before shutdown occurs. When a step deceleration occurs, the control initiates the following sequence of events: a.

Power is immediately reduced to idle, causing the engine to decelerate as rapidly as possible.

b.

When the engine reaches idle speed, the control holds it at idle for 10 seconds and then initiates a shutdown. The hold at idle allows the engine to be shut down from an on-schedule, stabilized condition.

c.

When the control initiates the shutdown after the 10 second idle hold, the following events occur:

•

The fuel shutoff valves are closed

•

Underspeed and oil pressure alarms are bypassed

•

Drain and vent valves are opened per control sequencing

•

Alarms, interlocks, sequence timers, and operating timers are reset

8-3.3.4 Slow Deceleration to Idle/Shutdown A slow deceleration to idle involves the fuel control controlling GT deceleration. After idle is reached, the sequence of events is as follows: a.

8-2

When the engine reaches idle speed, the control holds it at idle for 10 seconds and then initiates a shutdown. The hold at idle allows the engine to be shut down from an on-schedule, stabilized condition.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

b.

When the control initiates the shutdown after the 10 second idle hold, the following events occur:

•

The fuel shutoff valves are closed

•

Underspeed and oil pressure alarms are bypassed

•

Drain and vent valves are opened per control sequencing

•

Alarms, interlocks, sequence timers, and operating timers are reset

8-3.3.5

Aborted Start/Shutdown

An aborted start is a shutdown that is initiated at any time during the start sequence when certain parameters exceed limits. During an aborted start, the control initiates the following events: a.

The fuel shutoff valves are closed.

b.

The ignition system and starter are deenergized.

c.

Underspeed and oil pressure alarms are bypassed.

d.

Drain and vent valves are opened per control sequencing.

e.

Alarms, interlocks, sequence timers, and operating times are reset.

f.

A purge cycle is initiated by the control, if applicable.

GEK 105054 Volume I

8-4

OPERATOR ACTION

In order to avoid engine damage or more severe protective action, the operator must address the causes of all alarms and determine corrective actions necessary to clear abnormal conditions. Consult the troubleshooting procedures in Chapter 9 of this manual before resuming normal engine operation. After a power cutback or shutdown, positive action to correct the cause is necessary. For any alarm or protective action, the following general procedures should be followed: a.

Acknowledge the alarm in the manner specified in the packager's manual.

b.

During an alarm-only condition, correct the problem, if in question, contact packager/GE M&I, before resuming normal operation. NOTE Reduce power, then shut down and correct the problem; refer to the packager's manual for more specific information. Do not continue operation in the alarm condition.

c.

After a power cutback, correct the problem before resuming operation at power. If recovery is not possible, shut down and correct the problem.

d.

After a normal shutdown, correct the problem before attempting a restart.

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8-3

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

IT IS CRITICAL THAT THE RESTART PROCEDURE, FOLLOWING AN EMERGENCY SHUTDOWN, FOLLOW THE SPECIFIC SEQUENCE OUTLINED IN CHAPTER 7 OF THIS VOLUME, SECTION 7-4.7.1, TO AVOID MAJOR ENGINE DAMAGE. e.

After emergency shutdown, correct the problem before attempting a restart. For restart procedure following an emergency shutdown, refer to Volume I, Chapter 7, Section 7-4.7.1 Hot Restarts.

f.

Enter appropriate comments in the engine log concerning any problems and corrective actions.

8-4.1

Special Gas Turbine Constraints NOTE

For GT’s with a 2-stage high speed power turbine (PT), refer to GEK 105052 for operating limits and troubleshooting for specific PT functions and conditions Under normal operating conditions, the gas generator (GG) is constrained by the operating limits published in the limits table in Chapter 7. Continuous operation between the alarm and shutdown or trip level should not be practiced. In the event that any of the following situations or events occur, the associated special action or limitation shall be followed in order to ensure the GG continued normal operation. These events may not be detected or may not be prevented by the customary protective devices of control systems:

•

Overtemperature during starting

•

Lube oil pressure

•

High speed stalls

•

Restart, following high power trip

8-4

•

No PT rotation

8-4.1.1 Overtemperature During Starting During starting and acceleration to idle, the cooling airflow to the components of the GG hot section are not sufficient to protect the metal at T5.4 alarm and trip levels specified in the limits table, refer to Chapter 7 (Engine Operation) and Chapter 9 (Troubleshooting). A lower T5.4 limit is therefore established, with higher levels acceptable, provided they exist for limited times. This shall be monitored by the operator. The over-temperature inspection, called for by entry into area B, requires hot section disassembly and inspection in a qualified facility. 8-4.1.2 Lube Oil Pressure The lube oil supply pressure limits given in the limit table (Chapter 7) are distress limits. Protective devices cannot reliably monitor supply pressure because the proper pressure is dependent on NGG, oil type, oil temperature, and number of oil jets. An operator must therefore derive a corrected oil pressure as directed on the appropriate pressure correction table (Chapter 7) to determine if the lube system is performing within the limits stated in each table. 8-4.1.3

High Speed Stall

The control system incorporates a stall detection feature that is intended to preclude continued operation in a stall condition, once a stall is detected. However, stalls incurred at GG rotational speeds above 7,500 RPM can result in compressor blade fracture. The GG can be operated after an inspection of compressor stages 3 through 6 verifies that blade tip clanging has not occurred. If tip clanging has occurred, further inspection and stress relief of the blades is required, which necessitates blade removal from the spool. It should be noted that a compressor stall may be secondary to another condition. A thorough inspection of the gas/turbine should be conducted before a restart is attempted.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

8-4.1.4 Restart Following High Power Trip Restarts following an emergency shutdown or trip from operation at power may be restricted, depending on cause. Refer to Chapter 7, paragraph 7-4.7 for restart requirements. 8-4.1.5 No Power Turbine Rotation A thermally bound PT rotor could occur under extreme conditions following a rapid shutdown from high power. PT rotation should initiate during GT acceleration to idle. If rotation does not occur, the following procedure should be used: a.

Remain at idle for 30 seconds and shutdown.

b.

Restart and repeat step a.

c.

Restart and repeat step a.

d.

Restart and accelerate to 6800 rpm. Do not exceed 6800 rpm. Power turbine rotor should break away. If not, shut down and investigate for unlatched or shingled blades, or other cause.

Change 1

8-5/(8-6 Blank)

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 9 Troubleshooting 9-1

PURPOSE AND SCOPE

This chapter provides general troubleshooting procedures for the LM2500+ SAC gas generator/turbine. 9-2

ARRANGEMENT AND USE

This chapter includes three major segments: Engine Troubleshooting, a Troubleshooting Reference Table, and a set of numbered Troubleshooting Procedures. For ease of use, the Troubleshooting Reference Table and Troubleshooting Procedures follow these introductory and explanatory sections. Figures and tables are presented at the end of the section. Figure 9-1 (Sheets 1 through 7) and Tables 9-1 through 9-10 provide supplementary information for some of the numbered Troubleshooting Procedures. 9-2.1

Engine Troubleshooting WARNING

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE GAS GENERATOR/TURBINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON GAS GENERATOR/COMPONENTS, WITH POTENTIAL IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE GAS GENERATOR AND INJURY TO PERSONNEL.

CAUTION WHEN TROUBLESHOOTING ENGINE, DO NOT EXCEED MINIMUM AND MAXIMUM OPERATING LIMITS IN CHAPTER 7, TABLE 7-1. FAILURE TO COMPLY MAY CAUSE ADDITIONAL ENGINE MALFUNCTIONS. NOTE If troubleshooting procedures do not isolate and eliminate the fault, contact the Customer Service Department of General Electric Marine and Industrial Engines for assistance. 9-2.1.1

Introduction

Troubleshooting is a systematic analysis of symptoms that could indicate equipment malfunction. These symptoms usually appear as deviations from normal values of observed equipment parameters. Effective troubleshooting requires an intimate knowledge of the engine, its systems, and its interrelated effects. As a guide to intelligent troubleshooting, the most probable troubles and their possible symptoms are presented in this section. To assist in troubleshooting, operation of the packager’s controls should be understood. For this information, refer to packager’s instructions. Begin troubleshooting at the control panel for suspected engine faults. Trouble-shooter should be knowledgeable of the suspected troubled area. Troubleshooter should ensure the instruments used are calibrated and working properly, and have been accurately read and interpreted.

9-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-2.1.2 Gas Generator Speed Instrumentation Functional Check

9-2.3

a.

Check pin to pin resistance and pin to case of each sensor and each cable. See Tables 91 through 9-10.

b.

If sensor and cable resistances are within limits, check for proper gap setting on speed pickup. Refer to WP 105 00. If gap is out of limits, adjust and recheck voltage. If gap is within limits, replace pickup.

c.

Motor gas generator. At maximum motoring speed, voltage should be 30 - 70 volts peak-to-peak, sinewave at 10 kW load.

The Numbered Troubleshooting Procedures (TS-1 through TS-24) are referred to in the Troubleshooting Reference column of the Troubleshooting Reference Table. These procedures show symptoms for each engine or facility condition, possible causes for each, the troubleshooting procedure to isolate the cause of the problem, and the recommended corrective action. Events or conditions in the Troubleshooting Reference Table that have only a SPAM reference are not discussed in the numbered troubleshooting procedures.

d.

If cables and connectors are good, and installation gap is correct, check gas generator speed instrumentation at control system.

9-2.2

Troubleshooting Reference Table

The Troubleshooting Reference Table shows various problem events and system conditions, alarms, control actions, and the setpoints that trigger these alarms or control actions. These are grouped by major engine/facility systems. Each event also lists a numbered troubleshooting procedure (TS-) or a SPAM (See Packager's Appropriate Manual) reference. At the end of the Troubleshooting Reference Table are items in the Miscellaneous category. These either do not trigger an alarm or control action by themselves or are a combination of conditions. Some combinations may or may not trigger an alarm/control action by themselves, but must be looked at in combination with others.

Numbered Troubleshooting Procedures

Table 9-10 shows maximum allowable instrumentation and accessory temperatures. 9-2.4

Using This Chapter

The steps shown below illustrate how to use this chapter for troubleshooting. Example - Alarm received for overtemperature in lube scavenge system: a.

Find the lube system entry in the Troubleshooting Reference Table Contents on page 9-3 and refer to page listed.

b.

Refer to Troubleshooting Procedure Contents on page 9-18. Find TS-10, as listed in the Troubleshooting Reference column.

c.

Follow the appropriate procedure for each possible cause listed in TS-10. NOTE Symptoms, possible causes, troubleshooting procedures, and corrective actions are grouped horizontally across each page, allowing each symptom or set of symptoms to have more than one possible cause. Each possible cause may also have more than one troubleshooting procedure, and each troubleshooting procedure may have more than one corrective action.

9-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Reference Table Contents Page Combustion System............................................................................................................

9-4

Compressor System............................................................................................................

9-8

Facility System...................................................................................................................

9-4

Fuel System........................................................................................................................

9-5

Low Pressure Turbine Air Inlet Temperature System........................................................

9-12

Lube System.......................................................................................................................

9-10

Miscellaneous Systems.......................................................................................................

9-15

Power Turbine Speed Indication System (6-Stage Power Turbine).....................................................................................................

9-13

Starting System...................................................................................................................

9-14

Troubleshooting Reference Table Notes............................................................................

9-16

Variable Stator Vane System..............................................................................................

9-7

Vibration Monitoring System............................................................................................

9-15

9-3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

Alarm

System/Event

X

One Sensor X

Flame Loss, One or Both Sensors

Power Supply Failure (ECU)

Alarm

System/Event

Lose power for > 100 msec

Shutdown or Emergency Shutdown

Both Sensors

Shutdown or Emergency Shutdown Slow Deceleration to Minimum Load

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Facility System

Step Deceleration to Idle

Combustion System

Troubleshooting Reference Table

X

Abort Start

Abort Start

7

Notes

7

Notes

SPAM

Troubleshooting Reference

TS-3 SPAM

Troubleshooting Reference

In order to avoid engine damage or more severe protective action, the operator must address the causes of all alarms and determine corrective actions necessary to clear abnormal conditions before continuing engine operation. Except where otherwise indicated, each event shown in this Table is accompanied by an alarm, regardless of whether it is accompanied by a control action. Limits are shown in the alarm column for events resulting in an alarm only. Events that have both an alarm and an accompanying control action will show the limits in the appropriate action column and an X in the alarm column. In cases where one limit triggers an alarm only and a higher limit triggers both an alarm and control action, the limits for each will be shown in the appropriate columns. In any case that has no particular limits and is simply an either/or condition, the alarm and/or control action will be indicated by X in the appropriate columns.

Troubleshooting Reference Table GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-4

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

X

Fuel Supply Temperature, High

X

X

Loss of 1 Signal (Input: xxxAFAIL or xxxBFAIL)

Difference Fault (Input: xxx DFFAIL1)

Fuel Metering System

Fuel Supply Pressure (Upstream of Both Fuel Shutoff Valves), Low and High

Fuel Supply Pressure, Sensor Failure (Upstream of Both Fuel Shutoff Valves)

X

Alarm

Fuel Shutoff Valve Cycling

System/Event

X

Shutdown or Emergency Shutdown

> 350°F (177°C) Gas > 160°F (71.1°C) Liquid

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Fuel System

> 350°F (177°C) Gas > 160°F (71.1°C) Liquid

X

Abort Start

Troubleshooting Reference Table - (Cont.)

24

7

4, 7

Notes

SPAM

SPAM

SPAM

SPAM

SPAM

TS-17 SPAM

Troubleshooting Reference

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-5

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

One Sensor: < 10 psia, > 740 psia (< 69 kPa, > 5,102 kPa)

X

Servo Null Shift (Input: Servo Feedback)

Gas Pressure (Upstream of Metering Valve)

X

Servo Failure Open or Closed (Input: Servo Feedback)

SS Position Error (Input: I xxxDMD-xxxSEL

X (Steady State for > 0.5 sec)

Both Sensors: < 10 psia, > 740 psia (< 69, kPa, > 5,102 kPa)

E

E (Steady State for > 0.5 sec)

X

Position Error (Input: I xxxDMD-xxx-

SEL I

E

X

Loss of Both Sensors (Input: xxxAFAIL and xxxBFAIL)

E

X

Alarm

Difference Fault (Input: xxx DFFAIL2)

Fuel Metering System (Cont.)

System/Event

Shutdown or Emergency Shutdown

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Fuel System - (Cont.)

Abort Start

Troubleshooting Reference Table - (Cont.)

7, 30

15

15

15

15

Notes

SPAM

SPAM

SPAM

SPAM

SPAM

SPAM

SPAM

Troubleshooting Reference

GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-6

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

X

X

X

X Δ > 6.0%

Loss of Both Sensors (Input: VSVAFAIL and VSVBFAIL)

Position Error (Input: IVSVDMD - VSVSELI)

SS Position Error (Input: IVSVDMD - VSVSELI)

X < -2.0% or > 102%

Loss of 1 signal (Input: VSVAFAIL or VSVBFAIL)

Difference Fault (Input: VSVDFFAIL)

Alarm

System/Event

N Δ > 10%

N < -2.0% or > 102%

Shutdown or Emergency Shutdown

X

X

X Δ > 6.0 %

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Variable Stator Vane System

Abort Start

Troubleshooting Reference Table - (Cont.)

12

11, 15

8, 15

6

2

Notes

TS-18

TS-18

TS-18

TS-18

TS-18

Troubleshooting Reference

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-7

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

> 18°F (-8°C)

One Element: < -70°F, > 140°F (< -57°C, > 60°C)

< 8 psia, > 16 psia (< 35 psia, > 110 kPa)

< -40°F, > 1,200°F (< -40°C, > 649°C)

1 Sensor Element: > 40°F ( 22°C)

T2 A/B Difference Over Limit

T2 Sensor Failure, One or Both Elements

P2 Sensor Failure

T3 Sensor Failure

T3 Difference Over Limit

X

Stall

One Sensor: < 10 psia, > 480 psia (< 69 kPa, > 3,310 kPa)

PS3 Sensor Failure, One or Both Sensors

X

> 10 psia (69 kPa)

PS3 A/B Difference Over Limit

PS3 Over Pressure Limit

Alarm

System/Event

-dPS3/dt > Threshold for > 20 msec

> 375 psia (2,586 kpa)

Both sensors: < 10 psia, > 480 psia (< 69 kPa, > 3,310 kPa)

> 15 psia (> 103 kPa) for > 100 msec

Shutdown or Emergency Shutdown Step Deceleration to Idle

Both < -40°F, > 1,200°F (< -40°C, > 649°C)

Both Elements: < -70°F, > 140°F (< - 57°C, > 60°C)

Slow Deceleration to Minimum Load

Compressor System

Both

X

X

Abort Start

Troubleshooting Reference Table - (Cont.)

27

28

TS-7, TS-21

TS-7, TS-21

SPAM

TS-21

3, 9, 15 5

TS-21

TS-6

SPAM

SPAM

SPAM

Troubleshooting Reference

27

7, 18, 19

7

3, 7, 30

7, 27

Notes

GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-8

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

I A-B I > 37.5 rpm

NGG A/B Sensor Mismatch

26

26

7

Slow Acceleration to Maximum Power with High or Low T48

NGG Overspeed

X

26

26

10, 27

3, 7, 29

Notes

Acceleration to Maximum Power Not possible

X

X

Abort Start

Idle Speed Instability

Slow Deceleration to Minimum Load

19, 26

> 10,200 rpm

Both Sensors: < 0 rpm, < 1,700 rpm with > T48 > 400°F (204°C) and fuel on (Add > 11,500 rpm separately to each)

Step Deceleration to Idle

Idle Speed Too High or Low (NGGR)

> 10,100 rpm corrected

One Sensor: < 0 rpm, < 1,700 rpm with > T48 > 400°F (204°C) and fuel on

Gas Generator Speed (NGG) Sensor Failure, One or Both Sensors

No NGG Indication

Alarm

System/Event

Shutdown or Emergency Shutdown

Compressor System - (Cont.)

Troubleshooting Reference Table - (Cont.)

TS-16

TS-15

TS-15

TS-15

TS-15

TS-22

TS-22

TS-22

Troubleshooting Reference

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-9

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

< 0 psig, > 140 psig (< 0 kPa, > 965 kPa)

> 200 F (93°C)

Lube Scavenge Pressure Sensor Failure

Lube Supply Overtemperature

24

> 110 psig (758 kPa) at NGG > 4,950 rpm

Lube Scavenge Pressure High

Lube Scavenge Pressure Low

SPAM

16, 24

< 0 psid, > 50 psid (< 0 kPa, > 345 kPa)

Lube Scavenge, Lube Supply, or VG Filter Diff Pressure Sensor Failure

9-10

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page. TS-12 SPAM

SPAM

TS-11

TS-11

TS-21

3, 30

Both Elements: < -35°F, > 390°F (< -37°C, > 199°C)

One Element: < -35°F, > 390°F (< -37°C, > 199°C)

Lube Scavenge or Supply Temp Sensor Failure, Any Sensor (Any Sump, TGB Assy)

TS-10

TS-10

26

7

TS-9

TS-14

TS-14

Troubleshooting Reference

Fluctuating Lube Scavenge Temp

X

> 300°F (149°C)

Lube Scavenge Overtemp (Any Sump, TGB Assy)

> 340°F (171°C)

16

> 20 psid (138 kPa)

Notes

Lube Scavenge, Lube Supply, or VG Filter Diff Pressure High (Impending Bypass)

Abort Start

26

Slow Deceleration to Minimum Load

26

Step Deceleration to Idle

High Oil Consumption

Alarm

Oil Contamination

System/Event

Shutdown or Emergency Shutdown

Lube System

Troubleshooting Reference Table - (Cont.) GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

N < 100 ohms N < 100 ohms N < 100 ohms N < 100 ohms

X

X

X

X

C-Sump Chip Detected (Input: CSUECDDET)

D-Sump Chip Detected (Input: DSUECDDET)

TGB Chip Detected (Input: TGBECDDET)

AGB Chip Detected (Input: AGBECDDET)

N < 100 ohms

X

< 90°F (< 32°C) at NGG > 6,050 rpm

Lube Supply Temp Below Min

< 0 psig, > 140 psig (< 0 kPa, > 965 kPa)

B-Sump Chip Detected (Input: BSUECDDET)

One Sensor: < -35°F, > 390°F (< -37°C, > 199°C)

Lube Supply Temp Sensor Failure

Lube Supply Pressure Sensor Failure

X

Both Sensors: < -35°F, > 390°F (< -37°C, > 199°C)

7, 24

Notes

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page. 15

15

15

15

15

33

3

7, 24

25, 26

Abort Start

No Oil Pressure

< 6.0 psig (41 kPa) at NGG > 4,500 rpm

Slow Deceleration to Minimum Load

26

< 15 psig (103 kPa) NGG > 8,000 rpm < 8 psig (55 kPa) at 4,500 < NGG < 8,000 rpm

Lube Supply Pressure Low (With/Without Fluctuation)

Step Deceleration to Idle

Normal Lube Oil Pressure With Fluctuations > 5 psi

Alarm

System/Event

Shutdown or Emergency Shutdown

Lube System - (Cont.)

Troubleshooting Reference Table - (Cont.)

TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-12 SPAM

TS-21

SPAM

TS-13

TS-13

TS-13 SPAM

Troubleshooting Reference

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-11

21, 22

10, 20, 22, 23

< -40°F ( -40°C) < 350°F, > 1,900°F (< 177°C, > 1,038°C)

I T max -T min I > 200°F (111°C)

Loss of Any Individual T48 Probe

T48 Difference

X < 400°F (< 204°C)

X

T48 Temperature Average (T48 Avg) Under Limit

< 400°F (204°C) for > 10 sec with Fuel on (Gas) or 20 sec (Liquid)

> 1,500°F (816°C) NGG < 5,000 rpm

7, 20

20

7, 20

X

> 1,600°F (871°C) for > 1.0 sec

Hot Start: T48 Start Temperature Over Limit

> 1,600°F (871°C) for > 1.0 sec

> 1,150°F (621°C) (3,600 rpm Power Turbine)

T48 Temperature Average (T48 Avg) Over Limit

Notes

24

Abort Start

< 10 psia, > 90 psia (< 69 kPa, > 621 kPa)

Slow Deceleration to Minimum Load

P5.4 Sensor Failure

Step Deceleration to Idle

26

Alarm

Post-Shutdown Fire

System/Event

Shutdown or Emergency Shutdown

Low Pressure Turbine Air Inlet Temperature System

Troubleshooting Reference Table - (Cont.)

TS-8

TS-8

TS-8 TS-19

TS-1

TS-8

SPAM

TS-2

Troubleshooting Reference

GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-12

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

One Sensor: < 0, < 1,000, > 4,500 rpm

NPT Sensor Failure

X

Alarm

System/Event

NPT Overspeed

< -40°F (-40°C) < 350°F, > 1,900°F (< 177°C, > 1,038°C) or T48 Difference > 350°F (177°C)

Step Deceleration to Idle

Slow Deceleration to Minimum Load Abort Start

> 3,960 rpm

Both Sensors: < 0, 4,500 rpm

Shutdown or Emergency Shutdown Step Deceleration to Idle

Slow Deceleration to Minimum Load

X

X Both Sensors

Abort Start

Power Turbine Speed Indication System (6-Stage Power Turbine)

< 0.5 + P2SEL psia NGGSEL > 6,050 rpm

PT48 Pipe Failure

T48 Overshoot or Fluctuation at High-Power Steady-State

X

Alarm

Loss of Any Four T48 Probes or Loss of Three Adjacent T48 Probes (Loss of T48 Avg)

System/Event

Shutdown or Emergency Shutdown

Low Pressure Turbine Air Inlet Temperature System - (Cont.)

Troubleshooting Reference Table - (Cont.)

7, 28

3, 7, 14, 17, 30

Notes

26

24, 36

20, 21, 22, 23

Notes

TS-16

TS-22

Troubleshooting Reference

TS-8

SPAM

TS-8

Troubleshooting Reference

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-13

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

T48 < 400°F (204°C) at t > 10 sec (Gas) t > 20 sec (Liquid)

Operator Monitored

Lube Supply Pressure High

NGG < 4,600 rpm at t > 90 sec

NGG < 1,700 rpm at t > 30 sec (Gas) t > 20 sec and < 1,200 rpm (Liquid)

NGG < 6,000 rpm at t > 120 sec

Abort Start

Gas Generator Fails to Light Off

X

NGG Failure to Reach Starter Cutoff Speed

Slow Deceleration to Minimum Load

NGG < 1,200 rpm at t > 20 sec

X

NGG Failure to Reach Fuel and Ignition Speed

Step Deceleration to Idle

Engine Fails to Motor/ No Indication of Motoring

X

Alarm

NGG Failure to Reach Idle Speed (Hung Start)

Starting Stall

System/Event

Shutdown or Emergency Shutdown

Starting System

Troubleshooting Reference Table - (Cont.)

25, 26

26

Notes

TS-19

TS-19

TS-13 SPAM

TS-19

TS-19

TS-19

TS-1 TS-6

Troubleshooting Reference

GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-14

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

> 4 mils DA or 1.5 in/sec (3.8 cm/ sec) below 125 Hz for > 1.0 sec > 1.75 in/sec (4.4 cm/sec) above 125 Hz for > 1.0 sec

> 7 mils DA or 0.75 in/sec (1.9 cm/sec) below 45 Hz for > 1.0 sec > 1.25 in/sec (3.2 cm/sec) above 45 Hz for > 1.0 sec

Alarm

High Vibes, Gas Generator Frequency

High Vibes, Power Turbine Frequency

System/Event

Shutdown or Emergency Shutdown

Slow Deceleration to Minimum Load

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Miscellaneous Systems

> 10 mils DA or 1.5 in/sec (3.81 cm/sec ) below 45 Hz for > 0.1 sec > 1.75 in/sec (4.4 cm/sec) above 45 Hz for > 0.1 sec

> 7 mils DA or 2.5 in/sec (6.9 cm/ sec) below 125 Hz for > 0.1 sec> 3.0 in/sec (7.6 cm/sec) above 125 Hz for > 0.1 sec

Step Deceleration to Idle

Abort Start

Abort Start

Notes

Notes

Troubleshooting Reference

TS-20

TS-20

Troubleshooting Reference

TS-24

TS-2

High HP Rotor Speed, Low Power, and High or Low T48

Post-Shutdown Fire

29

TS-24

Loss of Performance

Events listed in this section are conditions that are not specifically handled by the engine control system or which are not part of any of the specific engine or package systems shown previously in this table. These events are either a single symptom or a combination of symptoms with no specific set of setpoints that can be monitored by the control. These events and conditions must be monitored by the operator and corrected as they occur. The combinations of conditions shown in this section do not cause any sort of alarm or control action to be initiated; however, individual symptoms that are part of any of the combinations shown here may cause an alarm or control action, just as they normally would when occurring alone (such as low pressure).

Alarm

System/Event

Shutdown or Emergency Shutdown

Vibration Monitoring System

Troubleshooting Reference Table - (Cont.) LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-15

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

Abort Start

Remove from average.

Control system defaults to remaining sensor/element.

Defaults to fully closed, zero fuel flow position.

Defaults to 14.69 psia (101.3 kPa).

> 1.0 second and NGGSEL > 4,950 rpm. Select lower sensor.

Emergency shutdown: Close fuel shutoff valves and CDP bleed valve.

Step to idle then shutdown. Set VSVMA to 0.0 mA.

Control system defaults to T2 = 115°F (46°C), if both sensors fail.

I Means Absolute Value I, the value of a number, regardless of a prefix plus or minus sign e.g., I -100I= 100.

> 1.0 second and NGGSEL > 4,950 rpm. Step to idle then shutdown. Set VSVMA to 0.0 mA.

> 5.0 seconds and NGGSEL > 4,950 rpm and I NGGDOT I < 150 rpm/sec and BRNDMD=BRNREQ for 5.0 seconds.

> 0.5 second, set VSVMA to 0.0 mA. Step to idle then shutdown.

NGG > 7,000 rpm for < 1,000 rpm/unit.

Shutdown: E: Emergency shutdown, N: Normal shutdown.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Troubleshooting Reference Table Notes

Slow Deceleration to Minimum Load

Limit and timer are adjustable.

Cavity Pressure < 50 psia (344.8 kPa) at P5.4 > 60 psia (413.7 kPa)

Low PT Thrust Balance Cavity Pressure

Step Deceleration to Idle

1.

Alarm

System/Event

Shutdown or Emergency Shutdown

Miscellaneous Systems - (Cont.)

Troubleshooting Reference Table - (Cont.)

Notes

TS-24

Troubleshooting Reference

GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-16

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

T48 is the average of individual T48 probe outputs, subject to rejection criteria of Note 24.

If < -40°F (-40°C), remove from average. Gas generator speed (NGG) > 5,000 rpm for < 350°F (177°C) limit.

Any T48 thermocouple probe reading is rejected from the T48 average calculation if it is:

20.

21.

22.

Reject from spread calculations any thermocouple probe reading that is out of range.

Defaults to last good value.

Reference Chapters 7 and 11 for normal/abnormal lube oil pressure determination.

This condition or combination of conditions requires operator intervention, but does not, by itself, cause the control system to initiate any sort of action.

Defaults to higher signal.

Failed element removed from average.

Defaults to 2,000 rpm, if both sensors fail.

Defaults to last good value, if both sensors fail.

NGG > 4,600 rpm for 0.5 second. NGGSEL > 4,950 rpm.

Defaults to minimum select.

Load addition inhibited by control at lube supply temperature less than 90°F (32°C).

Normal shutdown following deceleration to minimum load.

I Demand rate I < 50 percent per second.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

350°F (177°C) from T48 average

Refer to the appropriate packager's manual for control schedules, logic, and limits.

19.

(b)

Shutdowns caused by stall detection or variable-geometry system faults require borescope inspection of the gas generator. Refer to Volume II of this manual for inspection procedures.

18.

Out of range; T48i < 350°F(177°C) for NGG > 7,500 rpm or > 1,900°F (1,038°C)

This alarm/shutdown is enabled 60 seconds after reaching gas generator idle during the starting sequence.

17.

(a)

Alarm limits are based on component capability and may be reduced, consistent with the characteristics of each installation. For application and site specific conditions, refer to package’s manual.

16.

Troubleshooting Reference Table Notes - (Cont.) LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-17

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedure Contents Page TS-1:

Hot Start.......................................................................................................

9-19

TS-2:

Post-Shutdown Fire......................................................................................

9-20

TS-3:

Flameout.......................................................................................................

9-20

TS-4:

Electrical Power Supply Failure...................................................................

9-21

TS-5:

Fuel Supply Temperature.............................................................................

9-21

TS-6:

Stall..............................................................................................................

9-22

TS-7:

T3 (High Pressure Compressor Discharge Temperature)............................

9-23

TS-8:

T48 (LPT Inlet Temperature).......................................................................

9-24

TS-9:

Lube Supply/Scavenge Filter Differential Pressure....................................

9-25

TS-10:

Lube Scavenge Temperature.......................................................................

9-26

TS-11:

Lube Scavenge Pressure.............................................................................

9-27

TS-12:

Lube Supply Temperature...........................................................................

9-27

TS-13:

Lube Supply Pressure..................................................................................

9-28

TS-14:

Lube System - Miscellaneous......................................................................

9-31

TS-15:

Gas Generator (NGG) Speed.......................................................................

9-33

TS-16:

Gas Generator and Power Turbine Overspeed............................................

9-34

TS-17:

Gas Fuel System Problems..........................................................................

9-34

TS-18:

Variable-Geometry Systems........................................................................

9-35

TS-19:

Miscellaneous Starting Problems................................................................

9-35

TS-20:

Engine Vibration.........................................................................................

9-40

TS-21:

Temperature Sensors...................................................................................

9-41

TS-22:

Speed Sensors.............................................................................................

9-42

TS-23:

Flame Sensor...............................................................................................

9-43

TS-24:

Miscellaneous Problems..............................................................................

9-43

9-18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures TS-1: Hot Start NOTE Do not repeat hot starts without prior thorough investigation. Symptoms

Possible Causes

Troubleshooting

Corrective Action

Starting stall; T48 increase plus NGG hang-up or dropoff

Excess starting fuel flow

SPAM: Check calibration of fuel flow

T48 high after lightoff and during first portion of start cycle

Acceleration fuel flows too high or low

SPAM: Check PS3 sensor system

T48 start temperature over limit

VSVs off-schedule

TS-18

T48 start temperature over backup start schedule limit

HPT severe degradation

Borescope engine per WP 406 00

Repair HPT, if out of specified borescope limits

Compressor dirty

Borescope engine per WP 406 00

Water-wash engine per WP 405 00

Compressor severe degradation

Borescope engine per WP 406 00

Repair HPT, if out of specified borescope limits

Fuel metering valve supply pressure exceeds upper/ lower limits

SPAM

Starter cutout speed too low

SPAM

Starter air/gas/hydraulic supply pressure too low (Starter should drive gas generator @ > 2,000 rpm)

TS-19

Any of the above

Perform engine overtemperature inspection per WP 412 00

NOTE Also see TS-6 for starting stalls.

Reset cutout setting or replace starter

SPAM: Check starter supply system regulation Replace engine, if out of specified overtemperature limits

9-19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-2: Post-Shutdown Fire Symptoms T48 rise during normal shutdown T48 > 1,000°F ( > 538°C) after shutdown

Possible Causes

Troubleshooting

Corrective Action

Leaking fuel shutoff valve(s)

SPAM: Close valves, one at a time, to isolate faulty valve

Turn fuel off at isolation valve Motor gas generator with starter and ignition off until T48 indicates 400°F (204°C) or less. Do not exceed starter duty cycle Replace valves as required Borescope gas generator per WP 406 00, if T48 exceeds 1,000°F (538°C)

Sensor system failure

TS-21 TS-3: Flameout

Symptoms

Possible Causes

Troubleshooting

Corrective Action

TS-23

Flame loss, both sensors Flame loss

Sensor system failure

T48 < 400°F (204°C)

Low or no fuel flow or fuel pressure

SPAM: Check fuel system SPAM: Check PS3 sensor system

Fuel metering valve failed to close

SPAM

Fuel shutoff valves closed inadvertently and latched

SPAM: Check power to shutoff valve

Loss of T48 average signal in control

SPAM

SPAM Clean/replace as required

9-20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-4: Electrical Power Supply Failure Symptoms No control indications

Possible Causes

Troubleshooting

Electrical power supply loss to control

SPAM

Component failure in power supply

SPAM

Corrective Action SPAM: Repair/replace power supply as required

TS-5: Fuel Supply Temperature Symptoms

Possible Causes

Troubleshooting

Corrective Action

Gas fuel below Tsv limit

Sensor system failure

SPAM

SPAM: Inspect fuel metering valve for hydrates

Fuel supply temperature high

Sensor system failure Fuel cooler system failure

If temperature exceeds 700°F (371°C), fuel system hose life may be affected SPAM

SPAM Replace hoses and other temperature-sensitive fuel system components per appropriate work package

9-21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-6: Stall CAUTION BEFORE STARTING AN ENGINE THAT HAS EXPERIENCED A HOT START, A PRESTART MOTORING CHECK MUST BE PREFORMED TO DETERMINE IF FUEL MANIFOLD PRESSURE IS WITHIN LIMITS. REFER TO THE APPROPRIATE VOLUME 1, CHAPTER 7 AND ADDENDUM FOR SPECIFIC ENGINE MODEL BEING OPERATED. NOTE A starting stall is characterized by a hung start, slow acceleration to idle, lower than normal fuel manifold pressure (or fuel flow) and higher than normal power turbine inlet temperature (T48). Occasionally, the stall will continue at idle power. A stall at idle can be recognized by one or a combination of any of the following symptoms: higher than normal T48, higher than normal fuel manifold pressure, or NGG does not increase or is sluggish when power is advanced from idle. Symptoms Audible stall in operation Starting stall Shutdown with stall indication as first fault

Possible Causes All causes

Troubleshooting Borescope engine per WP 406 00

VSV system off- schedule VSV system worn/damaged

Inspect VSV per WP 414 00

Control system failure Starting system failure FOD

Ice on inlet screen or inlet bellmouth High inlet flow distortion Flooded plenum

Corrective Action Repair as required, if out of borescope inspection limits

TS-18

SPAM (Control System) SPAM

TS-19

Borescope engine per WP 406 00 Determine source of FOD Inspect inlet system per WP 401 00

Repair engine if out of borescope limits

Inspect inlet bellmouth screen and plenum Borescope engine for ice damage per WP 406 00 SPAM: Inspect antiicing system

Repair anti-icing system Melt ice with portable heater Repair compressor if damage is not within acceptable limits

CAUTION

BORESCOPE ENGINE BEFORE, RATHER THAN AFTER, WATERWASHING. WASHING BEFORE BORESCOPE MAY CAUSE ADDITIONAL DAMAGE, IF FOD ALREADY EXISTS.

9-22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-6: Stall - (Cont.) Symptoms (Cont.) Audible stall Starting stall Shutdown with stall indication as first fault

Possible Causes

Troubleshooting

Corrective Action

Inlet restricted by foreign objects other than ice

Remove obstructions and check screen for damage. If there is the possibility that objects have passed through the screen, borescope engine for FOD per WP 406 00.

High or low fuel manifold pressure

TS-17

Dirty compressor

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00

Water-wash engine per WP 405 00

Internal distress not visible by borescope

All of the above

If all procedures above fail to show cause of problem, engine shall be replaced

TS-1

Repair compressor if FOD exceeds limits Clean inlet and collector

TS-7: T3 (High Pressure Compressor Discharge Temperature) Symptoms High T3 for power and T2 levels (all elements)

A/B difference over limit Sensor failure

Possible Causes

Troubleshooting

Corrective Action

Dirty HPC

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00

Water-wash engine per WP 405 00

Damaged HPC

Borescope engine per WP 406 00

Repair as required

Control system failure

SPAM: Check to see if engine is operating on PS3 on a hot day

SPAM

Sensor system failure

TS-21

Replace T3 sensor as required

9-23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-8: T48 (LPT Inlet Temperature) Symptoms T48 average over limit

Possible Causes T48 system failure

Troubleshooting

Corrective Action

TS-21 SPAM

Single probe temperature over limit T48 max - T48 min spread exceeds 200°F (93°C)

T48 average under limit

Fuel nozzle condition

TS-21

HPC and HPT degradation Fuel supply pressure low (starting only) Excess fuel flow (starting only) Flameout

Borescope HPC and HPT per WP 406 00 SPAM

Repair or replace, as required, per WP 101 00. If hot T48, borescope HPT per WP 406 00 Repair as required

TS-3 SPAM

T48 system failure

TS-21 SPAM

Loss of average reading

T48 system failure

TS-21 SPAM

Loss of any individual probe(s) Higher T48 reading than previous reading at same power under same operating conditions; all other parameters changed with T48

Sensor failure(s) Cable failure(s) Control system failure VSV system off schedule

TS-21 SPAM

Replace probe/cable as required per WP 108 00

Check VSV system per

TS-18

Check T2 and TS-21 SPAM T48 sensor failure

TS-21

Compressor dirty

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00 Borescope HPC and HPT per WP 406 00

FOD Hot section deterioration

Water-wash engine per WP 406 00 Repair/replace as required Repair/replace as required

9-24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-8: T48 (LPT Inlet Temperature) - (Cont.) Symptoms

Possible Causes

T48 overshoot or fluctuation at high power steady-state

Troubleshooting

Sensor system or indicator failure

TS-21

Fuel supply system failure

Check fuel pressure

Worn or unstable fuel metering valve/control system

SPAM

Corrective Action

SPAM SPAM

TS-9: Lube Supply/Scavenge Filter Differential Pressure Symptoms High differential pressure alarm High differential pressure shutdown Increasing pressure drop with time Sensor failure: pressure less than zero or over sensor limits

Possible Causes Contaminated filter element

Troubleshooting

Corrective Action

Inspect filter per WP 400 00

Clean/replace filter element as required (for pump) per WP 400 00

Locate source of contamination

Correct source of contamination SPAM

Bearing or gearbox failure

Check pump screens and, if installed, check chip detectors per WP 400 00

Clean/replace pump screens and chip detectors as required (for pump) per WP 400 00

Sensor system failure

SPAM

TS-21 Increased oil viscosity or oil temp below normal

Check oil sample for viscosity per WP 407 00 SPAM: Check oil temp control valve

Replace oil, if necessary Repair as necessary

9-25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-10: Lube Scavenge Temperature Symptoms

Possible Causes

Troubleshooting

Corrective Action

Shift in scavenge temperature - all sumps

High lube supply temperature

SPAM: Check lube oil cooler and control valve

Repair or replace per packager's manual

Shift in individual scavenge temperature > 30°F (17°C) at constant power

Bearing failure

Check lube and scavenge pump screens for bearing material per WP 400 00

Repair/replace engine as required

Sensor system failure

TS-21

Oil supply leak, internal or external Low oil supply pressure

Check for high oil consumption; check for external leak

Sump air/oil seal failure Loss of pressurization Overtemperature: dark oil in tank samples; burned odor; sludge and varnish on oil filter; sludge on chip detector

Repair leaks; repair or replace engine as required Repair or replace engine as required

Low oil level in lube tank

SPAM Check oil level in tank

Drain, flush clean, and service lube/hydraulic system and all filters

Degraded oil

Check oil sample

Clean chip detector as required per WP 400 00 Refill tanks to correct level; monitor scavenge temperature when operation resumes

Low oil flow in sumps

Check corrected lube supply per Chapter 5; check sump temperature rise

Replace engine as required

Degraded lube pump output

Check lube supply pressure

Replace pump per WP 102 00 (5 element) or SWP 102 01 (6 element) as required

Check supply side filter

Clean/replace oil filter as required

Lube and scavenge pump inlet screens clogged with carbon

Clean lube and scavenge pump inlet screens per WP 400 00 Determine and eliminate cause of contamination High oil supply temperature

TS-12

SPAM

Sump air/oil seal failure

Check individual sump temperatures to isolate area of failure

Repair or replace engine as required

9-26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-10: Lube Scavenge Temperature - (Cont.) Symptoms Fluctuating lube scavenge temperature

Possible Causes

Troubleshooting

Sensor system failure

TS-21

Scavenge temp control valve cycling

SPAM

Corrective Action

TS-11: Lube Scavenge Pressure Symptoms Alarm on scavenge pressure Increasing scavenge pressure at constant power

Sensor Failure

Possible Causes Scavenge filter contaminated

Troubleshooting SPAM Check lube and scavenge pump screens per WP 400 00

Piping or heat exchanger fouled Scavenge interface not attached or obstructed Stuck check valve Improperly vented lube tank Cold oil

SPAM

Sensor system failure

SPAM

Corrective Action Replace filter as required per SPAM Determine and correct cause of contamination

SPAM Inspect check valve SPAM SPAM

Replace as required Warm oil with tank heater or by operating engine at low pressure

TS-12: Lube Supply Temperature Symptoms Overtemperature

Possible Causes

Troubleshooting

Oil cooler fouled Improper oil cooler temperature control

SPAM

High lube scavenge oil temperature

TS-10

Below minimum

Lube heater failure Improper oil cooler temperature control valve

SPAM

Sensor failure

Sensor system failure

TS-21

Corrective Action

SPAM

9-27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure Symptoms High pressure

Possible Causes

Corrective Action

Low oil temperature

Run engine long enough to warm oil at low power SPAM: Check operation of lube oil cooler control valve and/or lube tank heater

Sensor system failure

SPAM

Oil line blockage or kink

Check for crimped or blocked oil supply tubes downstream of pressure tap SPAM

Replace or clean oil lines as required

Clogged oil lines and jets, often indicated by tendency of pressure to creep upward

Monitor scavenge oil temperature and record any abnormal temperature to isolate problem area. Check lube and scavenge pump screens and chip detectors per WP 400 00

Clean oil lines Replace engine

Low oil tank level

SPAM

Replenish

Oil leak

Check external components for leakage Check torque on all oil lines

Replace leaking components Retighten all loose fittings

Sensor failure

SPAM

Oil/water contamination

Check oil sample for milky appearance and for water content

SPAM Repair source of water entry into tank. Drain, flush, and refill oil system and clean or replace oil filters

Lube/scavenge pump relief valve failure

Check pump discharge pressure

Replace lube/scavenge pump per WP 102 00 or SWP 102 01

High supply filter pressure drop

SPAM: Check filter for contamination

NOTE Reference Chapter 7 for normal pressure which is a function of lube supply temperature, gas generator speed, lube oil type, and engine configuration.

Low pressure with fluctuation

Troubleshooting

SPAM

9-28 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure - (Cont.) Symptoms Low pressure - (Cont.)

Normal lube oil pressure with fluctuations > ±5 psi

NOTE Oil pressure fluctuation during transients is considered normal; however, the fluctuations should stop within 1 minute after a steady-state condition is established.

Possible Causes

Troubleshooting

Corrective Action

Obstructed or collapsed oil supply line to pump

Disconnect supply line at pump and check flow

Replace supply line

Check oil-in flex hose for deterioration

Replace oil-in flex hose

Check for obstruction in pump inlet

Remove obstruction from pump Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required

Internal oil leak (possible damage to oil seals)

Check for high oil consumption, drains, and frame vents Check for abnormal scavenge temperatures

Repair or replace engine as required

Lube/scavenge pump failure

Check lube discharge for oil flow Pump drive spline

Replace lube/scavenge pump per WP 102 00 or SWP 102 01

Sensor system failure

SPAM

Low oil tank level

SPAM

Oil/water contamination

Check oil sample for milky appearance and water content

Repair source of water entry into oil tank. Drain, flush, and refill oil system with fresh oil. Clean or replace oil filters

Clogged filter

Check oil filter ΔP

SPAM

Sensor system failure

SPAM

Blocked or defective pump inlet line

Disconnect supply line at pump and check flow

Replace supply line

Check oil-in flex hose for deterioration

Replace oil-in flex hose

Check for obstruction in pump inlet

Remove obstruction from pump Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required

9-29 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure - (Cont.) Symptoms (Cont.) Normal lube oil pressure with fluctuations > ±5 psi

Possible Causes

Troubleshooting

Defective lube/scavenge pump relief valve

Defective oil tank vent

Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required SPAM

Air-in system lines No oil pressure

Corrective Action

Run engine to purge air

Lube/scavenge pump failure Sheared pump shaft

Verify lube supply to pump. Check lube or scavenge discharge for oil flow Check for NGG indication while motoring engine

Replace lube/scavenge pump per WP 102 00 or SWP 102 01 Replace pump if NGG indication is present with no oil pressure and normal oil supply to pump

Low oil tank level

SPAM

Faulty oil pressure indication; faulty transmitter or pressure line

SPAM

Obstructed oil supply line to pump

Disconnect supply line and check for presence of oil Check oil supply flex hose for deterioration (collapsed or kinked) Check for obstruction in pump inlet Check for improperly connected lines or reversed check valve

Continue troubleshooting Replace hose Remove obstruction and clean tank Correct problem

Obstructed tank strainer

Remove inlet strainer and inspect for obstructions

Remove obstruction and clean oil strainer and tank

Loss of pump prime

Check pump inlet line for presence of oil

Fill oil line with oil as required

9-30 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-14: Lube System - Miscellaneous Symptoms Oil contamination

Possible Causes Maintenance error; lube tank serviced with contaminated oil

Troubleshooting Contact GE M&I Customer Service before continuing operation

CAUTION If engine is operated for more than 200 hours with lubricating oil containing more than 5% mineral oil, significant internal sump coking may occur.

Corrective Action Flush all lube and hydraulic systems until samples are clear of contaminants Completely drain oil tank and as many service lines as possible. Service with fresh lubricating oil and circulate system until clear of contaminants. Drain oil tank and lines and refill with fresh oil Motor engine and operate for 24 hours and re-sample oil to confirm cleanliness

Lube/scavenge pump failure Hydraulic pump failure

Check lube and hydraulic screens and system filters for debris per WPs 400 00 and 408 00

Flush lube and hydraulic systems Replace defective hydraulic pump per WP 120 00 or lube/scavenge pump per WP 102 00 or SWP102 01 as required

Engine bearing failure Starter failure

Check all scavenge screens, chip detectors, and system filters for debris (bearing debris plus increased engine vibration) per WPs 400 00 and 408 00

Flush lube and hydraulic systems Replace engine as required Replace starter as required

Defective oil cooler/heat exchanger

SPAM

Water-wash engine per WP 405 00 Tighten coupling nuts or replace defective parts as required

Oil tank not clean

SPAM

External piping degradation/corrosion

SPAM

9-31 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-14: Lube System - Miscellaneous - (Cont.) Symptoms High oil consumption

Possible Causes

Troubleshooting

Corrective Action

Records in error

Verify records

Correct records

Oil leak from combined actuator drain, lube pump, accessory drive pad drains, combined drain B- and C-sumps, starter drain, or external lines

Isolate source Maximum B-/C-sump drainage is 7.0 cm³/hr Maximum AGB pad, starter, actuator, and lube drainage is 7.0 cm³/hr

Isolate each individual drain from the gang drain to find source of leakage. Repair as required

Air/oil separator failure

Inspect lines, drains, and air discharge (no oil discharge expected)

Clean or replace as required per WP 116 00

Sump pressurization tube or vent line blockage or damage

Inspect all pressurization tubes and vents

Clean or replace as required

Lube pump failure (flooded sump)

Inspect pump and check discharge pressure per WP 400 00

Replace lube/scavenge pump per WP 102 00 or

Internal leakage

Inspect (borescope inspect) flowpath per WP 406 00 Inspect bellmouth per WP 401 00 Inspect exhaust per WP 404 00

Repair or replace

External leakage in off-engine system

SPAM

SWP 102 01

9-32 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-15: Gas Generator (NGG) Speed Symptoms

Possible Causes

Troubleshooting

Sensor mismatch No speed indication

Sensor system failure Sensor gap too large

TS-22

Idle speed too high/low

Stall

TS-6

T2 sensor failure

TS-21

Control failure

SPAM

Speed sensor system failure

TS-22

Fuel metering valve failure

SPAM

Fuel system failure

TS-19

VG system off schedule

TS-18

Gas fuel properties not constant

SPAM

Fuel metering valve/ECU failure

SPAM

Fuel supply pressure fluctuation

SPAM

Intermittent T2, NGG, or PS3 sensor output

TS-21 TS-22

Idle speed instability

SPAM

Corrective Action Replace sensor Reset to correct gap Replace sensor

SPAM: PS3 Accel to maximum power not possible or accel slow

Low or no fuel flow and fuel pressure

SPAM: Check - PS3 line to sensor - PS3 sensor circuit - Fuel flow vs PS3 schedule

VG system off-schedule

TS-18

Control system failure

SPAM

SPAM

9-33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-16: Gas Generator and Power Turbine Overspeed Symptoms NGG overspeed

Possible Causes

Troubleshooting

Control failure (without shutdown)

Perform overspeed inspection per WP 411 00 SPAM

Sensor system failure

TS-22

Corrective Action Replace gas generator, if damage exceeds limits SPAM

SPAM

NPT overspeed

Worn or unstable fuel metering valve

SPAM

Radial drive shaft failure

Attempt manual engine rotation from maintenance crank pad on aft end of TGB Assembly. View HPC rotor through borescope port per WP 406 00 to see if HPC rotates

Isolate and replace defective drive component per WP 207 00

High-speed coupling shaft failure

SPAM

SPAM

Control failure

Perform overspeed inspection per WP 411 00

Replace power turbine, if damage exceeds limits

Sensor system failure

TS-22 SPAM

TS-17: Fuel System Problems Symptoms

Possible Causes

Troubleshooting

Shutoff valve cycling

Control failure Valve failure Valve power failure

SPAM

Fuel manifold pressure too low at start

Fuel shutoff valve failure

SPAM

Fuel manifold pressure too high or low at power Speed/power instability

Fuel supply system failure

SPAM

Corrective Action

9-34 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-18: Variable-Geometry Systems Symptoms Position error Schedule limits exceeded

Possible Causes

Troubleshooting

Corrective Action

Low or no hydraulic pressure

Replace VSV control per WPs 100 00, 120 00, 121 00, and SPAM Replace VG pump per WP 120 00

Clean or replace filters/screens as required

LVDT or actuator failure

Check for open circuit

Replace actuator per WP 100 00

Binding in VSV system

Check per WP 418 00

Replace torque shaft per WP 114 00 as required

ECU

SPAM

TS-19: Miscellaneous Starting Problems Symptoms

Possible Causes

No start

Troubleshooting Reset control to get start permissive

Corrective Action SPAM

NOTE Deenergize ignition system and motor engine per packager's instructions to purge any gas in ducting. Do not exceed starter duty cycle if applicable. No start: NGG and fuel pressure OK

No start: NGG and ignition OK, but low or no fuel manifold pressure

Faulty ignition circuit(s)

Perform ignition system functional check per WP 409 00 SPAM

Repair or replace as required SPAM

Incorrect fuel quality

SPAM

Fuel supply pressure failure Fuel metering valve too far closed

Check vent valve positions Check fuel system pressures

SPAM: Correct as required

Fuel shutoff valves closed

Check fuel shutoff valve positions

Open fuel valves

9-35 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms

Possible Causes

Troubleshooting

Corrective Action

No start: NGG and ignition OK, but low or no fuel manifold pressure (Cont.)

Fuel system contamination

Disconnect supply lines and check for clogged upstream filters and/or contamination in supply lines

Flush contaminants from fuel supply lines Clean upstream filters

No start: NGG rises rapidly to starter cutout speed

Sheared radial drive shaft, or IGB spline sheared

Crank engine from maintenance pad on aft end of TGB assembly. View rotor through borescope port per WP 406 00 to see if HPC rotates

Isolate and replace defective drive component per WP 207 00

Failure to light off

Same as above

Same as above

Ignition system failure

Perform ignition system functional check per WP 409 00 SPAM

Low starter air, gas, or hydraulic pressure output

SPAM

Speed sensor system failure

TS-22

Radial drive shaft or starter failure

Check drive shaft and starter SPAM

Low or no fuel flow and fuel pressure

SPAM: Check -PS3 line to sensor(s) -PS3 sensor circuit -Fuel flow vs PS3 schedule

Fuel contamination

Disconnect supply lines and check for clogged upstream filters or air and/or contamination in supply lines

VG position off-schedule

TS-18

Failure to reach idle speed on start (hung start) Failure to reach starter cutout speed Failure to reach fuel and ignition speed on start

NOTE The above symptoms may be accompanied by low fuel flow and low T48.

Replace igniters per WP 103 00 SPAM

SPAM Service, repair, or replace starter (GE only) per WP 117 00 SPAM Repair or replace radial drive shaft per WP 207 00

Flush contaminants from fuel supply lines Clean upstream filters

9-36 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms Failure to reach idle speed on start (hung start) (Cont.)

No start, no NGG indication, no oil pressure

Possible Causes

Troubleshooting

Corrective Action

HP compressor damage

Borescope per WP 406 00

Repair or replace engine as required

Start stall/hot start

TS-1 TS-6

Starter air, gas, or hydraulic pressure below limits Starter inoperative

SPAM: Check starter air, gas, or hydraulic supply pressure Check starter spline drive

Increase pressure to proper limit, or replace starter if pressure is OK

Faulty starter gas, air, or hydraulic shutoff valve

SPAM: Check starter gas, air, or hydraulic valve control voltage and valve pressure

Restore power supply or replace faulty component

Faulty start selector switch or open circuit breaker

SPAM: Check start selector switch and circuit breaker

Replace switch and/or reset circuit breaker

Seized gas generator rotor

Check rotor rotation with starter or with ratchet wrench on TGB assembly maintenance crank pad

Attempt another start after cool-down period and/or rotation check

Borescope for evidence of damage to HPC/HPT per WP 406 00

Repair or replace engine as required

Check for binding, rubs, etc. Check chip detectors and scavenge screens per WP 400 00

9-37 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms

Possible Causes

Troubleshooting

Corrective Action If vane has become disengaged or rotated and has grooved HPC rotor, vane shall be removed and replaced per WP 212 00. Depth of the HPC rotor groove shall also be inspected. If groove is through the alumina coating, gas generator shall be replaced

No start, no NGG indication, no oil pressure (Cont.)

Seized gas generator rotor

Check VSV system for mechanical integrity; verify that there is no vane rotation and that no vane tip is digging into HPC rotor

No start, no NGG indication

NGG sensor system failure

TS-22

Engine fails to motor, but control indicates motoring; rapid increase in indicated motoring speed

Radial drive shaft failure

Attempt manual rotation through maintenance crank pad on aft end of TGB assembly. Borescope per WP 406 00 to see if HPC rotates

Isolate and replace defective drive component per WP 207 00

Engine fails to motor/no indication of motoring or fails to reach maximum motoring speed

Seized engine

For cold engine, check rotation with starter or with ratchet wrench on TGB assembly maintenance crank pad Borescope engine per

Attempt another start and/or rotation check after 30 minute cool down period Repair or replace engine

WP 406 00

If installed, check chip detectors per WP 400 00 GG speed sensor engagement incorrect

Check sensor gap per WP 105 00

Repair or replace as necessary per WP 105 00

Speed sensor system failure

TS-22

Repair or replace as required

9-38 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms

Possible Causes

Troubleshooting

Corrective Action

Engine fails to motor/no indication of motoring or fails to reach maximum motoring speed - (cont.)

Low starter supply pressure Starter exhaust blockage (pneumatic starter)

SPAM

Starter failure

Attempt manual engine rotation through gearbox; if engine rotates, problem is in starter system

Service, repair, or replace starter per WP 117 00 or SWP 117 01 (GE starter only); otherwise, SPAM

Accessory failure

Remove gearbox-driven accessories one at a time and attempt manual engine rotation, after each accessory is removed

If engine will rotate after removal of an accessory, replace the failed accessory

Accessory gearbox failure

If engine will not turn after removal of all accessories, remove radial drive shaft per WP 207 00. Rotate accessory gearbox

Replace accessory gearbox per WP 206 00

FOD

If starter and drive train operate properly, but engine will not rotate, borescope engine per WP 406 00

Repair or replace engine as required

Bearing or seal failure

Check chip detectors for debris; check sump scavenge screen in lube and scavenge pump for evidence of bearing or seal failure

Repair or replace engine as required

9-39 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-20: Engine Vibration Symptoms

Possible Causes

Troubleshooting

Corrective Action

High vibes, gas generator (alarm) High vibes, power turbine (alarm)

Sensor system failure

Perform functional check per WP 410 00 SPAM

Repair or replace accelerometers as required per WP 111 00 SPAM

High vibes, gas generator (shutdown) High vibes, power turbine (shutdown)

Rotor imbalance

Using vibration measuring instrumentation with frequency-scanning type filter, determine predominant frequency. If frequency is same as gas generator (power turbine), problem is probably gas generator (power turbine) caused

Replace gas generator (power turbine) if vibes > alarm levels and no other cause is found

Engine not mounted securely

SPAM: Check all engine mount systems

SPAM: Realign and tighten mounts

Bearing failure

Check chip detectors for metal particles per WP 400 00 Check oil scavenge inlet screens for metal particles per WP 400 00

Repair or replace engine as required Repair or replace engine as required

FOD

Borescope engine per WP 406 00

Repair or replace engine as required

Compressor or turbine damage

Inspect compressor inlet area per WP 401 00 Borescope engine per WP 406 00

Repair or replace engine as required

Loose sensor/mounting

Inspect sensor mounting system

Repair sensor mount

High speed coupling shaft or driven load unbalance

SPAM

9-40 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-21: Temperature Sensors Symptoms T48 - Loss of average reading T48 - Cold sensor

Possible Causes Sensor or cabling failure, Type K thermocouple

T48 - Loss of three adjacent probes T48 - Loss of four probes T48 - Loss of any probe T48 - High or over limit T48 max - T48 min spread exceeds 200°F (93°C)

Signal-conditioning or display failure System ground loop

Sensor or cabling failure, Type K thermocouple Signal-conditioning or display failure System ground loop

Water, oil, or corrosion on electrical connector pins or sockets

Fuel nozzle condition

Troubleshooting Table 9-4 Table 9-5 SPAM SPAM

Corrective Action Repair or replace as required per WP 108 00 SPAM

Table 9-4 Table 9-5 SPAM Table 9-4 Table 9-5 SPAM SPAM

Repair or replace as required per WP 108 00 SPAM

Table 9-4 Table 9-5 SPAM Inspect for contaminants on electrical pins or sockets If no contaminants are found, proceed to fuel nozzle condition troubleshooting Identify highest and lowest reading T48 probes Identify fuel nozzle affecting the temperature of highest and lowest reading T48 probes (See Figure 9-1A) Mark locations of these fuel nozzles and remove for inspection per WP 101 00

Repair or replace as required per WP 108 00 SPAM

Repair or replace as required per WP 108 00 SPAM

Clean/replace as required

9-41 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-21: Temperature Sensors - (Cont.) Symptoms (Cont.) T48 max - T48 min spread exceeds 200°F (93°C)

Possible Causes (Cont.) Fuel nozzle condition

T3 sensor failure T3 A/B difference over limit

T2 sensor failure T2 A/B difference over limit

Sensor or cabling failure, Type K thermocouple Signal-conditioning or display failure Sensor or cabling failure, RTD, see Table 9-6

Lube supply or scavenge temperature sensor failure

Signal-conditioning or display failure Sensor or cabling failure, RTD, see Table 9-7

RTD A/B difference excessive

Signal-conditioning or display failure

Troubleshooting Inspect for clogging or burning If no clogging or burning is noted, swap positions of removed fuel nozzles by installing fuel nozzles from lowest reading probe upstream of highest reading probe and vice versa per WP 101 00 Operate engine and check effect of this change. Repeat previous steps as required Table 9-4 Table 9-5

Corrective Action Clean/replace as required

Repair or replace as required per WP 123 00 SPAM

SPAM Table 9-4

Table 9-5

Repair or replace as required per WP 109 00 SPAM

SPAM Table 9-4 Table 9-5 SPAM

Repair or replace as required per WP 110 00

TS-22: Speed Sensors Symptoms NGG sensor failure NGG sensor mismatch

NPT sensor failure NPT sensor mismatch

Possible Causes Sensor system failure

Signal-conditioning or display failure Same as above

Troubleshooting Check sensor resistance per Table 9-9 Check sensor gap per WP 105 00 Check sensor voltage per paragraph 9-2.1.2 SPAM

Corrective Action Repair or replace as required per WP 105 00

Same as above

Same as above

9-42 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-23: Flame Sensor Symptoms Flame loss, one sensor (alarm) (no flameout) Flame loss, two sensor (shutdown)

Possible Causes Sight glass lens dirty Sensor lens dirty Sensor failure

Troubleshooting Inspect lenses

Corrective Action Clean or replace as required per WP 118 00

Verify operation with UV light source

Replace sensor as required per WP 118 00

Wiring

SPAM: Check package connections from sensor to package signal conditioner SPAM: Check system voltages Switch sensor inputs at amplifier to determine whether problem follows sensor

Repair or replace as required

Signal conditioner failure

SPAM

TS-3 TS-24: Miscellaneous Problems Symptoms Loss of performance

Possible Causes Compressor dirty High inlet filter pressure drop VSV system off- schedule FOD

High NGG rotor speeds at low power low T48

Normal deterioration due to normal operation, consistent with total operating time VSV system offschedule closed Compressor dirty FOD

High NGG, low power, high T48

Compressor dirty VSV system offschedule CDP bleed off-schedule

Troubleshooting Inspect inlet per WP 401 00 Borescope compressor per WP 406 00

Corrective Action Water-wash engine per WP 405 00

TS-18 Borescope engine per WP 406 00 Borescope engine per WP 406 00

Repair or replace engine as required Refurbish as required

TS-18 Borescope inspect compressor per WP 406 00 Borescope engine per WP 406 00 Inspect inlet per WP 401 00 Borescope compressor per WP 406 00

Repair or replace engine as required Water-wash engine per WP 405 00

TS-18 SPAM

9-43 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Troubleshooting Procedures - (Cont.) TS-24: Miscellaneous Problems - (Cont.) Symptoms

Possible Causes

Low PT thrust balance cavity pressure (alarm)

Troubleshooting

Air supply leaks Worn PT balance piston seal

SPAM: Check for air leaks and verify accuracy of indication system

Corrective Action If no leaks or indication error, replace orifice plate per Volume II, WP 431 00

Table 9-1. LVDT/Torque Motor Resistance Values for TS-18 Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms±10%)

Corrective Action

VSV Actuator Valve LVDT

9-1 (Sheet 6)

E40 Connectors 2 and 3

2-3 4-5 6-7

Primary Sec Y Sec Y

Replace VSV Actuator per

E46 E47

A-B

VSV Servovalve

9-1 (Sheet 7)

WP 100 00

Replace VSV Servovalve per WP 121 00

* At room temperature or as specified in tables. Table 9-2. Flame Detector Resistance Values Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms±10%)

Corrective Action

Flame Detectors

—

—

1-2

511

Replace flame detectors per WP 118 00

* At room temperature or as specified in tables. Table 9-3. Accelerometer Resistance Values Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms±10%)

Corrective Action

CRF/TRF Accelerometer with Integral Leads

9-1 (Sheet 8)

E13/E1

1-2 1-case 2-case

N/A 1.0 MΩ min 1.0 MΩ min

Replace accelerometer per WP 111 00

* At room temperature or as specified in tables.

9-44 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 9-4. Temperature Sensor Resistance Values for TS-21 Sensor

Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms)

T48 Type K Thermocouple (T/C)

Sensors

9-1 (Sheet 1)

T/C #1 T/C #2 T/C #3 T/C #4 T/C #5 T/C #6 T/C #7 T/C #8

KN-KP

0.44 to 0.83

—

Terminal to case

1.0 MΩ min

Measure both terminals to case

E21A/ E21B

1-1 2-2 3-3 4-4 5-5 6-6 7-7 8-8 Pin to shield

Continuity

May be measured at either end of the on-engine harness (at connector)

1-1 2-2 3-3 4-4 5-5 6-6 7-7 8-8

Continuity

On-engine harness

Off-engine cabling

T3 Type K T/C

9-1 (Sheet 1)

N/A

SPAM

Comments

1.0 MΩ min

Table 9-5 1.0 MΩ min

Sensor/ harness

9-1 (Sheet 3)

E30A/ E30B

A-B C-D Terminal to shield

2.1-2.6 2.1-2.6 1.0 MΩ min

Off-engine cabling

N/A

SPAM

A-A B-B C-C D-D

Table 9-5 Table 9-5 Table 9-5 Table 9-5

May be measured at either end of the on-engine harness (at connector)

9-45 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9-4. Temperature Sensor Resistance Values for TS-21 - (Continued)

Sensor

Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms)

Comments

T2 RTD

Sensor

9-1 (Sheet 6)

E40

1-2 3-4

Table 9-6 Table 9-6

Standard and optional sensors each have two 100-ohm @ 32°F (0°C) RTDs in each probe. Each probe has an integral lead

On-engine cabling

9-1 (Sheet 6)

E40

Any lead 1-18 2-19 3-20

Continuity

May be measured at either end of the onengine harness (at connector)

Sensor

9-1 (Sheet 4)

E3C/E3D E4C/E4D E5C/E5D E18C/E18D E6C/E6D E11C/E11D

1-2 3-4

Table 9-7 Table 9-7

Sensors each have two 100-ohm @ 32°F (0°C) RTDs in each probe.

Off-engine cabling

N/A

SPAM

Any lead

Continuity

May be measured at either end of the onengine harness (at connector)

Lube RTDs

* At room temperature or as specified in tables.

9-46 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 9-5. Cable Circuit Resistance Values At Room Temperature (or as specified in Tables) Cable Length (ft)

Table 9-7. Lube RTD Resistance Values Temperature

Resistance (Ohms)

Resistance

(°F)

(°C)

(Ohms ±10%)

-40.0

-40.0

84

1.1 - 1.8

0.0

-17.8

92

4.0 - 6.4

1.7 - 2.7

32.0

0.0

100

40

5.3 - 8.6

2.2 - 3.6

50.0

10.0

104

50

6.7 - 10.7

2.8 - 4.4

60

8.0 - 12.9

3.4 - 5.3

100.0

37.8

115

150.0

35.6

126

200.0

93.3

137

250.0

121.1

150

300.0

148.9

159

KP

KN

10

1.3 - 2.1

0.5 - 0.9

20

2.6 - 4.3

30

Table 9-6. T2 Resistance Values Temperature

Resistance

(°F)

(°C)

(Ohms ±10%)

-40

-40

84

0

-18

92

350.0

176.7

170

32

0

100

400.0

204.4

181

50

10

104

100

38

115

200

93

137 Table 9-8. Lube System Chip Detector

Component

Reference Figure

Chip Detector

9-1 (Sheet 5)

Interface E41 E42 E43 E44 E45

Component Pins

Resistance (Ohms)

Corrective Action

1-2

1.0 MΩ

Pin to case

> 1.0 MΩ

Low resistance indicates chip or short. Replace detector

9-47 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9-9. Speed Sensor Resistance Values

Component NGG

Reference Figure 9-1 (Sheet 2)

NPT

9-1 (Sheet 2)

Interface E7/E12

E14/E15

Component Pins

Resistance (Ohms ±10%)

1-2 1-2 Pin to case

200

A-B A-B Pin to case

80 (L21656P04) 950 (L44630P01) 1.0 MΩ

1.0 MΩ

Table 9-10. Maximum Allowable Instrumentation and Accessory Temperatures Components

Temperature

Lube Oil RTDs

220°F (104°C)

NGG Speed Sensor

225°F (107°C)

Variable Stator Vane Actuators

350°F (177°C)

Accelerometers

500°F (260°C)

T48 Sensor (At Lugs)

600°F (316°C)

T3 Sensor (At Connector)

600°F (316°C)

Lube Pump

300°F (149°C)

Starter

250°F (121°C)

UV Flame Detectors

200°F (93°C)

NPT Speed Sensor

600°F (316°C)

9-48 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E21A and E21B (Sheet 1 of 8) 9-49 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 9-1. Electrical System Schematic Interface E7, E12, E14, and E15 (Sheet 2 of 8) 9-50 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E30A and E30B (Sheet 3 of 8)

9-51 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 9-1. Electrical System Schematic Interface E3C, E4C, E5C, E6C, E11C, and E18C (Sheet 4 of 8)

9-52 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E41, E42, E43, E44, and E45 (Sheet 5 of 8) 9-53 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 9-1. Electrical System Schematic Interface E40 (Sheet 6 of 8) 9-54 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E46 and E47 (Sheet 7 of 8)

Figure 9-1. Electrical System Schematic Interface E1 and E13 (Sheet 8 of 8)

9-55 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 9-1A. Fuel Nozzle/T48 Probes Relationship 9-56 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 10 General Maintenance Practices •

Left - the side opposite the right side

This chapter covers general maintenance practices and procedures to be followed during all maintenance operations.

•

Top - the side of the engine that is up when the engine is in the normal operating position

10-2

•

Bottom - the side of the engine on which the gearboxes are mounted

•

Clock Positions - the positions of the numbers on a clock face, as seen from aft looking forward. 12:00 o'clock is at the top, 3:00 o'clock is on the right side, 6:00 o'clock is at the bottom, and 9:00 o'clock is on the left side.

10-1

PURPOSE AND SCOPE

LEVELS OF MAINTENANCE

The workscope for level 1 corrective maintenance allows replacement of external parts, adjustments, and other work (preventive and corrective) up to and including removal and replacement of the entire engine. The workscope for level 2 corrective maintenance permits the replacement of major engine sections (modules) and the replacement or repair of certain internal parts. Level 2 maintenance is performed on-site on a noninstalled engine or on an installed engine in the enclosure, as permitted by the enclosure design. Maintenance is performed with the engine horizontal. See Volume II. 10-3

POINTS OF REFERENCE

10-4 STANDARD MAINTENANCE PRACTICES 10-4.1

WARNING

•

THE FOLLOWING STEPS MUST BE PERFORMED BEFORE ENTERING THE ENCLOSURE. THESE CONDITIONS MUST BE MAINTAINED WHILE INSIDE THE ENCLOSURE TO PREVENT INJURY TO PERSONNEL.

•

THE FIRE EXTINGUISHING SYSTEM MUST BE DEACTIVATED BEFORE PERSONNEL ENTER THE ENCLOSURE. SUFFOCATION CAN OCCUR IF THE FIRE EXTINGUISHING SYSTEM IS ACTIVATED.

The following points of reference are used throughout this manual: forward, aft, right, left, top, bottom, and clock position. These points of reference are defined as follows:

•

Forward - the air intake end of the engine

•

Aft - the exhaust end of the engine

•

Right - the right side of the engine, when viewed from the aft end and when the engine is in the normal operating position (gearbox down)

Safety

Observe all safety precautions listed below, as well as those listed in Chapter 1 and Chapter 7.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-1

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Wear protective clothing, gloves, safety glasses, etc., as required by the maintenance to be performed. Ensure that the engine will not be started while personnel are inside the enclosure. Post an observer at the exit, while maintenance is being performed inside the enclosure. WARNING

•

•

WHEN PERFORMING MAINTENANCE ON ELECTRICAL COMPONENTS, AVOID SHOCKS AND BURNS BY TURNING OFF ELECTRICAL POWER TO THOSE COMPONENTS, EXCEPT WHEN NECESSARY TO TAKE VOLTAGE MEASUREMENTS. TAG ELECTRICAL SWITCHES OUT OF SERVICE, TO PRECLUDE INADVERTENT ACTIVATION. TAG THE ENGINE OPERATING CONTROLS DO NOT OPERATE, TO PREVENT STARTING DURING A DESIRED SHUTDOWN CONDITION.

Turn off all electrical power, fuel, and air service to system on which maintenance is to be performed. Allow the engine to cool. Confirm that gas fuel lines have been vented/purged. The following steps must be performed upon exiting the enclosure after completion of maintenance: a.

Ensure that no personnel are inside the enclosure.

b.

Close the enclosure door.

10-2

c.

Turn on electrical power, fuel, and air services.

d.

Activate fire extinguisher system.

10-4.2

Tools and Tasks

All hardware items have been manufactured to English measurement units. Use of substitute metric sizes is not recommended and will void the warranty for interfacing parts. Tools in metric sizes should be furnished with suitable adapters to mate with English measurement unit sizes given. Limits, fits, and clearances may be interpreted in either English or metric units, as shown in the tables. NOTE Most of the tasks outlined can be done within the enclosure, if the horizontal maintenance option is selected, provided that tooling is available. Deviations from the procedures in the Volume II work packages are permitted, as necessary, to adapt to the needs dictated by the enclosure design, provided that these deviations do not compromise the intent of the instruction. Some modular change-outs may be done within the enclosure and some outside, whichever is more convenient. Consult the packager for planning assistance when questions arise. 10-4.3

Torque

In these maintenance procedures, all threaded parts on the engine will be tightened to a specific torque value. Special torque values, if required, will be stated in the text; otherwise, standard torque values should be used.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Torque values are expressed in lb in. (poundinches), lb ft. (pound-feet), or N•m (Newtonmeter). One pound-inch (or 1.0 pound-foot) is the twisting force of 1.0 pound applied to a twist-type fastener (such as a bolt or nut) with 1.0 inch (or 1.0 foot) of leverage. This twisting force is applied to the fastener to secure the components. N•m is the metric version of this applied force. It is important to use the correct torque wrench for the amount of torque being applied. See Table 10-1 for torque wrench ranges and requirements.

GEK 105054 Volume I

CAUTION IF TORQUE SHOULD INCREASE SIGNIFICANTLY PRIOR TO FINAL SEATING OF ANY THREADED FASTENER, REMOVE AND INSPECT THE FASTENER FOR THE CAUSE OF THE TORQUE INCREASE. Never over-torque any fastener. Torque limits are provided in the text and in Tables 10-2 through 10-5; these limits must be observed. Refer to paragraph 10-4.3.1 for application information. Do not use lubricant on bolt threads unless specified in assembly procedures. Start threads at least two turns by hand to ensure proper engagement.

Table 10-1. Torque Wrench Ranges and Requirements Torque Range

Torque Wrench Capacity

0 - 25 lb in.

(0 - 2.8 N•m)

0 - 30 lb in.

(0 - 3.4 N•m)

25 - 140 lb in.

(2.8 - 15.8 N•m)

0 - 150 lb in.

(0 - 16.8 N•m)

140 - 550 lb in.

(15.8 - 62.1 N•m)

0 - 600 lb in.

(0 - 67.2 N•m)

30 - 140 lb ft

(40.7 - 189.8 N•m)

0 - 150 lb ft

(0 - 203.4 N•m)

140 - 240 lb ft

(189.8 - 325.4 N•m)

0 - 250 lb ft

(0 - 339.0 N•m)

240 - 1000 lb ft

(325.4 - 1356.0 N•m)

0 - 1000 lb ft

(0 - 1356.0 N•m)

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10-3

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 10-2. Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts Torque Value

Size

Threads Per Inch

lb in.

N•m

8

32

13 - 16

1.5 - 1.8

10

24

20 - 25

2.3 - 2.8

1/4

20

40 - 60

4.5 - 6.8

5/16

18

70 - 110

7.9 - 12.4

3/8

16

160 - 210

18.1 - 23.7

7/16

14

250 - 320

28.2 - 36.2

1/2

13

420 - 510

47.5 - 57.6

8

36

16 - 19

1.8 - 2.1

10

32

33 - 37

3.7 - 4.2

1/4

28

55 - 70

6.2 - 7.9

5/16

24

100 - 130

11.3 - 14.7

3/8

24

190 - 230

21.5 - 26.0

7/16

20

300 - 360

33.9 - 40.7

1/2

20

480 - 570

54.2 - 64.4

10-4

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Table 10-3. Torque Values for Engine Plugs and Unions Tube OD (inches)

Fitting Dash No.

Torque Value

1/8

2

40 - 50 lb in.

(4.5 - 5.6 N•m)

3/16

3

90 - 100 lb in.

(10.2 - 11.3 N•m)

1/4

4

135 - 155 lb in.

(15.3 - 17.5 N•m)

5/16

5

155 - 175 lb in.

(17.5 - 19.8 N•m)

3/8

6

180 - 200 lb in.

(20.3 - 22.6 N•m)

1/2

8

270 - 300 lb in.

(30.5 - 33.9 N•m)

5/8

10

360 - 400 lb in.

(40.7 - 45.2 N•m)

3/4

12

45 - 50 lb ft

(61.0 - 67.8 N•m)

1

16

58 - 70 lb ft

(78.6 - 94.9 N•m)

1-1/4

20

75 - 87 lb ft

(101.7 - 117.9 N•m)

1-1/2

24

83 - 100 lb ft

(112.5 - 135.6 N•m)

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10-5

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 10-4. Torque Values for Tubing Nuts and Hose Fittings Hose Dash No. (Size)

Tube OD (Inches)

Aluminum Female Sealing Surfaces (See Note 1)

0.125

(1/8)

-2

–

0.1875

(3/16)

-3

30 - 50 lb in.

0.25

(1/4)

-4

0.3125

(5/16)

0.375

–

Steel Female Sealing Surfaces (See Note 2) 40 - 50 lb in.

(4.5 - 5.6 N•m)

(3.4 - 5.6 N•m)

90 - 100 lb in.

(10.2 - 11.3 N•m)

40 - 65 lb in.

(4.5 - 7.3 N•m)

135 - 155 lb in.

(15.3 - 17.5 N•m)

-5

60 - 80 lb in.

(6.8 - 9.0 N•m)

180 - 200 lb in.

(20.3 - 22.6 N•m)

(3/8)

-6

75 - 125 lb in.

(8.5 - 14.1 N•m)

270 - 300 lb in.

(30.5 - 33.9 N•m)

0.50

(1/2)

-8

150 - 200 lb in.

(16.9 - 22.6 N•m)

450 - 550 lb in.

(50.8 - 62.1 N•m)

0.625

(5/8)

-10

200 - 300 lb in.

(22.6 - 33.9 N•m)

650 - 770 lb in.

(73.4 - 87.0 N•m)

0.75

(3/4)

-12

25 - 35 lb ft

(33.9 - 48.0 N•m)

75 - 91 lb ft

(101.7 - 123.3 N•m)

1.0

(1)

-16

41 - 58 lb ft

(55.6 - 78.6 N•m)

112 - 128 lb ft

(151.8 - 173.5 N•m)

1.25

(1-1/4)

-20

50 - 75 lb ft

(67.8 - 101.7 N•m)

133 - 150 lb ft

(180.3 - 203.4 N•m)

1.5

(1-1/2)

-24

50 - 75 lb ft

(67.8 - 101.7 N•m)

158 - 183 lb ft

(214.2 - 248.1 N•m)

NOTES:

10-6

1.

These values apply when female sealing surface is aluminum. Male connector and nut may be either steel or aluminum.

2.

These values apply when female sealing surface is steel. Male connector and nut may be either aluminum or steel.

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GEK 105054 Volume I

Table 10-5. Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting Locknuts Torque Dash No. (Size)

Threads Per Inch

Size

lb in.

lb ft

N•m

2

0.3125

24

40 - 50

5.2 - 5.6

3

0.375

24

90 - 100

10.2 - 11.3

4

0.4375

20

135 - 155

15.3 - 17.5

5

0.50

20

155 - 175

17.5 - 19.8

6

0.5625

18

180 - 200

20.3 - 22.6

8

0.750

16

270 - 300

30.5 - 33.9

10

0.875

14

360 - 400

40.7 - 45.2

12

1.0625

12

540 - 600

45 - 50

61.0 - 67.8

16

1.3125

12

700 - 850

58 - 70

78.6 - 94.9

20

1.635

12

900 - 1050

75 - 87

101.7 - 117.9

24

1.875

12

1000 - 1200

83 - 100

112.5 - 135.6

10-4.3.1

Standard Torque

Use the following standard torque tables, unless otherwise directed in the text. Use the torque values given in Table 10-2 for steel bolts and nuts (including self-locking nuts). Values given are for clean bolts and nuts that are free of nicks and burrs. Use half the value given in Table 10-2 for the following applications:

•

Thin steel hex nuts

•

Non-steel nuts and bolts, except titanium.

•

All bolts threaded directly into aluminum, magnesium, or other non-steel parts.

Use the torque values given in Tables 10-3 and 10-4 for gasketed fittings. Install fittings as instructed in paragraph 10-4.6. Torque values given in Tables 10-3 and 10-4 are for packing made of synthetic material, asbestos compounds, or soft metal (copper, aluminum, etc.). These values do not apply to steel gaskets or special boss seals.

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10-7

GEK 105054 Volume I 10-4.3.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Running Torque

10-4.3.3

Refer to Table 10-6 for minimum running torque on self-locking nuts. This table applies to silver-plated, lubricated, and nonlubricated self-locking nuts. Values given are for nuts with no axial load. To check minimum running torque, screw the nut onto a bolt until two to five threads are exposed beyond the nut. Measure the amount of torque required to turn the nut on or off the bolt. Nuts that do not meet these minimum frictional requirements should be replaced.

Tightening Procedures CAUTION

WHEN CHILLING OR HEATING AN ENGINE PART DURING ASSEMBLY, DO NOT TORQUE SPANNER NUTS, LOCKNUTS, OR RETAINING BOLTS UNTIL THE PART HAS RETURNED TO ROOM TEMPERATURE. THE FASTENER MAY LOOSEN AS THE PART COOLS OR MAY BE OVERSTRESSED AS THE PART WARMS AND EXPANDS. If possible, tighten at a uniformly increasing rate until the desired torque is obtained. In cases where gaskets or other parts cause a slow permanent set, be sure to hold the torque at the desired value until the material is seated.

Table 10-6. Minimum Running Torque for Self-Locking Nuts Minimum Running Torque Threads/ Inch

Size

lb in.

N•m

0.136 (6)

32/40

1.0

0.11

0.164 (8)

32/36

1.5

0.16

0.190 (10)

32

2.0

0.22

1/4

28

3.5

0.39

5/16

24

6.5

0.73

3/8

24

9.5

1.07

7/16

20

14

1.6

1/2

20

18

2.0

9/16

18

24

2.7

5/8

18

32

3.6

3/4

16

50

5.6

10-8

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

CAUTION TORQUE SHALL BE LESS THAN THE FINAL TORQUE REQUIRED FOR THE SMALLEST DIAMETER BOLT. THIS PREVENTS SHEARING OR BREAKING OF TIGHT BOLTS DUE TO FORCE CONCENTRATIONS. Apply uniform torque to a series of bolts that have different diameters, and are installed on one flange or in one area. CAUTION IT IS NOT DESIRABLE TO TIGHTEN TO THE FINAL TORQUE VALUE DURING THE FIRST DRAWDOWN; UNEVEN TENSION CAN CAUSE DISTORTION OR OVERSTRESSING OF PARTS.

GEK 105054 Volume I

Torque mating parts by tightening the bolts or nuts gradually, until the parts are firmly seated. Loosen each fastener by one-quarter turn, then apply final tightening. Tightening in a diametrically opposite (staggered) sequence is desirable in most cases (Figure 10-1). Do not exceed listed maximum torque values. All bolts are installed with heads forward and up with nuts aft and down, unless otherwise specified. Washers are installed beneath the part that turns when tightening, unless otherwise specified. The torque wrenches listed in Table 10-1 are recommended for use within the indicated ranges. Larger wrenches have too great a tolerance and can result in inaccuracies.

Figure 10-1. Tightening Sequence for Threaded fasteners Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-9

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Torque values specified in this manual are actual values to be applied to fasteners. Whenever an adapter (crowfoot, spanner wrench, etc.) is used with a torque wrench, torque must be calculated per Figure 10-2. Inspect all nuts and bolts after tightening to make sure they are seated. If any nut or bolt is not seated after the required torque has been applied, remove and inspect for thread damage. Lubricate tube/hose connector threads and between the B-nut and ferrule of a connector. Run B-nuts onto fittings by hand to ensure that tubes and hoses are aligned and threads are free of burrs. Two wrenches must be used when loosening or tightening B-nuts, one on the fitting to which the tube or hose is being connected to hold it stationary and one on the B-nut for torquing. This not only prevents twisting the tube, but also prevents loosening or over-tightening the fitting. When using an extension on a torque wrench, calculate the correct torque input before applying torque per Figure 10-2. 10-4.4

Loose Fasteners

Prior to retightening, examine the fastener and the joint for the cause of the looseness. If safety wire or fastener is broken, ensure root cause for fastener/joint looseness is resolved before retightening. If safety wire is missing, tighten to the required torque and safety-wire the fastener. If the fastener has a self-locking feature, check breakaway torque per the preceding step. Replace defective fasteners as required.

10-10

10-4.5

Tri-Wing/Torx Fasteners

Tri-wing/torx recessed-head fasteners are available in a wide range of sizes and each size requires the use of a matched driver. See Figure 10-3. When properly used, the tri-wing/torx design permits a higher ratio of torque to end-pressure than is possible with slotted-head or cross-head designs, minimizing burring and mutilation. The following procedures should be used for tri-wing/torx fasteners: 10-4.5.1

Installation

Select the correct driver. The driver number should match the recess number of the fastener head as shown in Figure 10-3. Table10-7 lists a range of standard fastener sizes with their corresponding tri-wing/torx recess identification numbers. Table 10-7. Tri-Wing/Torx Drivers and Standard-Thread Fasteners Screw Thread Size

Tension Head

Shear Head

0 - 80

0

–

2 - 56

1

–

4 - 40

2

1

6 - 32

3

2

8 - 32

4

3

10 - 32

5

4

1/4 - 28

6

5

5/16 - 24

7

6

3/8 - 24

8

7

7/16 - 20

9

8

1/2 - 20

10

9

9/16 - 18

11

10

5/8 - 18

12

11

3/4 - 16

13

12

7/8 - 14

14

13

1 - 12

15

14

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Figure 10-2. Torque Wrench Correction Factor Determination Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-11

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-3. Tri-Wing/Torx Fastener Drive Be sure that the axis of the drive is aligned with the axis of the fastener when installing or removing the fastener. If the head of the fastener has been coated with paint or other material, use a driver one size smaller than that indicated, to compensate for the thickness of material on the walls of the recess. 10-4.5.2 Extraction There is no slope to the walls of mating surfaces of either fastener or driver, so that the tendency of the driver to slip out of the recess is minimized. Normal extraction by applying counterclockwise (CCW) torque is usually successful. If corrosion or other factors have caused the fastener to seize so that failure of the recess occurs, select the proper drill and screw extractor for the size of fastener involved. The bottom of the fastener recess is shaped so that the drill centers itself naturally and no special drilling procedure is required. Drill into the fastener 10-12

deep enough to provide sufficient working depth for the screw extractor. Tap the extractor to seat it firmly, then apply CCW torque to remove the fastener. 10-4.6 Universal Fittings Universal fittings should be installed according to the procedures described below. 10-4.6.1 Nonpositioning Fittings (See Figure 10-4.) a.

Lubricate preformed packing and roll it over the threads into the groove in the fitting.

b.

Screw the fitting into the boss until preformed packing contacts the surface of the boss.

c.

Tighten the fitting to the proper torque value.

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GEK 105054 Volume I

Figure 10-4. Nonpositioning Fittings 10-4.6.2 Positioning Fittings (See Figure 10-5.) a.

Screw the jamnut completely over the first section of threads on the fitting, past the packing groove, and onto the second section of threads.

b.

Lubricate preformed packing and roll it over the threads into the groove in the fitting.

c.

Turn jamnut until it just bears against preformed packing.

d.

Screw the fitting into the boss until preformed packing contacts the surface of the boss.

e.

Turn fitting to desired position by backing out not more than one turn.

f.

Attach the line to the fitting and check the alignment of the fitting.

g.

Hold the fitting and tighten the nut to the proper torque.

10-4.6.3 Bulkhead Fittings (See Figure 10-6.) a.

Attach bulkhead fitting to bulkhead with jamnut as shown in Figure 10-6.

b.

Connect tube or hose nut and tighten.

c.

Hold fitting with wrench and tighten jamnut to the specified torque value.

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10-13

GEK 105054 Volume I

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Figure 10-5. Positioning Fittings 10-14

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GEK 105054 Volume I

Figure 10-6. Bulkhead Fittings 10-4.7 Gaskets, Preformed Packings, and Expendable Parts Gaskets, preformed packings, key washers, and cotter pins shall not be reused, unless otherwise specified. Gaskets and preformed packings shall be lightly lubricated with engine lube oil prior to installation, unless otherwise specified. Ensure parts are properly seated. When a fitting with a jamnut and preformed packing is used, see Figures 10-4 and 10-5 for the proper installation procedure. See Figure 10-7 for preformed packing used with flexible sleeve type fittings.

10-4.8

Tubes

When installing tubes, the following precautions and instructions apply.

•

Apply engine lube oil between the tube nut and the ferrule, prior to tightening (see Figure 10-8). As tubes are installed, tighten all end fittings and clamps fingertight. After a complete system is installed, torque clamps first and then end-fittings.

•

Maintain a minimum clearance of 0.125 inch (3.18 mm) between tubes and adjacent parts.

•

Tubes and manifolds must fit within 0.063 inch (1.60 mm) radius in a free state during assembly, or be replaced.

•

Coupling nuts shall thread freely by hand.

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10-15

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-7. Flexible Coupling Assembly 10-16

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GEK 105054 Volume I

Figure 10-8. Rigid Tube

•

Mating flanges on tubes shall seal flush within 0.005 inch (0.13 mm).

•

The distance between faces of mating surfaces or flanges shall not exceed 0.063 inch (1.60 mm).

•

Bend tubes in existing straight sections, if possible.

•

Use bending tools on any tube 1.0 inch (25.4 mm) or more in diameter, to prevent the tube from collapsing. WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELLVENTILATED AREA.

•

On those couplings where sealant is required, carefully apply a thin coat of sealant to each face of gasket and coupling mating surfaces. Wipe off any sealant on inside of tube with a clean rag and water. Do not allow sealant to enter air systems.

10-4.9

Hoses

(See Figure 10-9.) No hose should be bent more than the bend radius specified in Table 10-8, because of possible damage to Teflon liners. Before installing hoses, visually inspect the hose interior to assure that the Teflon lining has not been damaged. If damaged, replace the hose. Kinked hoses must not be used. Preformed hoses or hoses of large diameter shall not be bent or straightened (see Figure 10-10). During installation, be sure that no hose is twisted or stretched. Never over-torque connectors. When hoses are removed, cap the open ends.

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GEK 105054 Volume I

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Figure 10-9. Installation of Hose Assemblies 10-18

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Table 10-8. Hose Minimum-Bend Radii Minimum-Bend Radius Dash Size

in

mm

3

1.5

38.10

4

2.0

50.80

5

2.0

50.80

6

4.0

101.60

8

4.62

117.348

10

5.5

139.70

12

6.5

165.10

16

7.38

187.452

20

11

279.4

24

14

356.6

32

22

558.8

GEK 105054 Volume I

Natural gas fuel hoses and fuel nozzle steam hoses have different and more restrictive requirements. Refer to the appropriate work package in Volume II for details. Fluid fittings shall be tightened gradually to the required torque value, backed off one-quarter turn, and then tightened again. Do not attempt to correct leaks by excessive tightening. Always use two wrenches when tightening swivel coupling nuts on hoses, tubes, or fittings. Hold the stationary part with one wrench while applying torque with second wrench.

Figure 10-10. Factory Preformed Hoses

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10-19

GEK 105054 Volume I 10-4.10

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Correction of Leaks CAUTION

DO NOT OVER-TORQUE THREADED FASTENERS AS A METHOD OF CORRECTING LEAKING CONNECTIONS. OVER-TORQUING COULD RESULT IN PART FAILURE. a.

Disassemble the connection.

b.

Discard the seal, gasket, or preformed packing, if present.

c.

Inspect mating surfaces for contamination, scratches, dents, or other surface defects.

d.

e.

Inspect threaded fasteners for thread damage and ensure that fasteners seat properly when tightened to specified values. Replace nonserviceable parts and assemble the connection, using new seals, gaskets, or preformed packings as required.

10-4.11

Clamps

Chafing of hoses and tubes must be avoided. Clamp parts loosely in place, shift the hoses until the best clearance is obtained, and then tighten the clamps (Figure 10-11). Clamps must be of the proper size for the piping to permit slippage during engine thermal growth. The cushion clamp liner position should also be checked before tightening the clamp (Figure 10-12). Clamps must be positioned over the wear sleeves on the tube.

10-20

10-4.12 10-4.12.1

V-Band (Coupling) Clamps Preinstallation Checks

Check alignment of tube ends, unrestrained, to the following maximum limits prior to installing V-band clamps:

•

Parallelism: no angle (centerlines of tubes or fittings parallel)

•

Offset between fittings or tube centerlines: no more than 0.06 inch (1.524 mm) circumferential, axial, or combined

•

Gaps: no more than 0.06 inch (1.524 mm) space between fitting seats

If tube ends do not align within the above limits, readjust mounting until proper alignment is attained. Check that flange faces are free of dirt, grease, corrosion, distortion, deformation, and scratches. Use protective flange caps on the ends of all ducts until the installation progresses to the point where removal of the cap is essential to continuing with the installation. Use care during the installation of ducts and tubes to ensure mating and alignment of flanges. A poorly fitted joint requires excessive torque on the T-bolt to close the joint and imposes structural loads on the V-band clamp. Adjacent support clamps or brackets should remain loose until installation of the coupling has been completed. When connections are by V-band couplings, the weight of the components should be fully supported during the fitup and installation of the couplings.

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GEK 105054 Volume I

Figure 10-11. Routing and Clamping Techniques

Figure 10-12. Installation of Cushion Clamps

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10-21

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

When reinstalling a used coupling, check it for twist or distortion. Visually check the V-section for spreading at the open ends or other signs of distortion. Check spot welds or rivets for condition and security. The corner radii should be carefully checked for tool marks and cracks. V-band couplings in poor condition should be replaced.

CAUTION

Check the threads on the T-bolt for wear and condition. If there is any sign of wear, galling, or deformation, install a new T-bolt or coupling clamp. Check the T-bolt for straightness; however, if it is bent, it will be necessary to determine if the bend is intentional. Some small diameter couplings have curved T-bolts. Check the applicable illustrated parts breakdown for part identification. If in doubt, install a new T-bolt or coupling clamp.

•

DO NOT USE PLIERS ON V-BAND CLAMPS TO FORCE ALIGNMENT OF TUBE ENDS WHILE ENGAGING V-BAND BOLTS AND NUTS. RESIDUAL STRESS IN THE TUBES AND NICKS, SCRATCHES, OR DEFORMATION IN THE CLAMPS, CAN CAUSE PREMATURE FAILURE OF THESE PARTS.

•

DO NOT SUBSTITUTE ANY OTHER COUPLING NUT FOR THE TYPE NUT SUPPLIED WITH THE COUPLING. THE CORRECT NUT (ESNA Z1200J SERIES) IS IDENTIFIED BY THE LETTER J STAMPED ON A WRENCH FLAT. FAILURE TO COMPLY MAY RESULT IN DUCT JOINT FAILURE.

Check the trunnion and latch for freedom of movement or other overloading.

a.

Place the V-band clamp over one of the tube ends far enough to clear the flange.

Avoid twisting, spreading, or bending of the coupling when positioning the coupling on the joint.

b.

Install the gasket, if required, and mate both flanges.

When gaskets are used in the joint, exercise care in handling to avoid nicks and burrs on the gasket surfaces. Whenever a joint is disassembled after service operations, a new gasket should be used when reassembling to ensure maximum sealing efficiency. Exercise care to ensure that the gasket is properly seated.

c.

Relocate the clamp over both flanges and press the clamp closed.

d.

Install the nut, check to ensure that the T-bolt is properly seated, and tighten the nut to approximately one-half of the required torque marked on the strap.

10-4.12.2

e.

Tap the clamp lightly around the circumference with a rubber mallet to equally distribute the load.

f.

Alternate tightening and tapping until torque stabilizes at the specified value. Avoid over-torquing.

g.

Inspect the clamp for even seating.

h.

See Figure 10-13 for safety-wiring the V-band clamp. Use 0.032 inch (0.81 mm) safety wire.

Installation

The following procedures should be followed to ensure proper V-band clamp installation:

10-22

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GEK 105054 Volume I

Figure 10-13. V-Band Clamps and Safety-Wiring Techniques 10-4.13

INSTALLED SEAL COULD AFFECT THE USEFULNESS OF THE SEAL AND/OR CONNECTOR.

Electrical Cables and Connectors

During electrical cable installation, adjust the cable through the clamps to get the smoothest and largest radius. Sharp bends, twists, and kinks must be avoided. Minimum clearance between the electrical cable and any component other than hoses or other electrical cables is 0.125 inch (3.18 mm).

c.

CAUTION

Some connectors have a seal ring located in the coupling nut (Figure 10-14), if so, inspect to make sure the seal is present and serviceable before attaching the connector. Replace unserviceable seals as follows: a.

Remove the unserviceable seal.

b.

Engage the new seal over the barrel of the connector CAUTION DO NOT ALLOW THE SEAL TO TIP AND FLATTEN. AN INCORRECTLY

Push the seal to its seated position against the internal shoulder in the connector using a mating connector or blunt screwdriver.

DO NOT FORCE THE CONNECTORS TOGETHER. IF THE PINS ARE NOT ALIGNED, THEY WILL BE BENT OR DISTORTED AND WILL NOT MAKE CONTACT. d.

Electrical connectors on flexible harnesses and leads shall be hand-tightened beyond finger-tight (20 degrees maximum) until connecting parts are in solid contact without damage. Safety-wire the connectors only when specified in the procedure.

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10-23

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-14. Electrical Connectors (Typical) e.

f.

If the connector is a locking connector, engage the connector and wiggle the backshell while tightening the coupling ring hand-tight. A clicking sound is produced during tightening of the connector. Ensure that the full coupling color band on the receptacle is not visible and that the backshell has no movement. Do not sharply bend, kink, or twist rigid leads. When tightening the connection, always hold both mating connectors to prevent damage to the leads.

10-24

10-4.14

Electrical Bonding Straps

Electrical bonding strap contact surfaces shall be prepared by removing all anodic film, grease, paint, lacquer, or other high-resistance material from an area at least one and one-half times the bonding surface contact area. Bonds shall be installed and contact surfaces sealed within 4 hours of cleaning. The area shall then be painted to match the surrounding area. NOTE The LM2500+ SAC package provides an interface (E16 and E17) for bonding lugs located at the power turbine mount bolts.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

10-4.15

Safety Wiring

Safety wiring is the securing of two or more parts with a wire installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire. This is not a means for obtaining or maintaining torque, but rather a safety device used to prevent the disengagement of parts. See Figure 10-15 for general safety-wiring practices.

GEK 105054 Volume I

•

Safety wire shall not be installed in a manner to cause the wire to be subjected to chafing, fatigue through vibration, or additional tension, other than the tension imposed on the wire to prevent loosening.

•

Both 0.020 inch (0.51 mm) and 0.032 inch (0.81 mm) safety wires are used throughout the engine. The application is determined by the size of the hole in the unit to be safety-wired. Whenever possible, use the 0.032 inch (0.813 mm) safety wire. Only new safety wire shall be used in each application.

•

The safety wire shall be pulled taut while being twisted, and shall have nine to 12 twists per inch (25 mm) for 0.020 inch (0.51 mm) diameter wire and seven to 10 twists per inch (25 mm) for 0.032 inch (0.81 mm) diameter wire.

•

Hose and electrical coupling nuts shall be safety-wired in the same manner as tube coupling nuts.

•

Caution must be exercised while twisting to keep the wire tight without overstressing it or allowing it to become nicked, kinked, or otherwise mutilated. Only existing safety wire should be replaced; do not add safety wire which was not previously in place or specified in text.

•

When removing safety wire, identify safety-wiring holes on parts.

NOTE

•

•

Although not every possible combination of safety wiring is shown in Figure 10-15, all safety wiring must, in general, correspond to the examples shown. General Electric (GE) gas turbines use special locking cables at some locations. When removed for maintenance, these should be replaced with equivalent cables or safety wire using standard safety-wiring procedures in this chapter.

10-4.15.1 Safety Wiring General Practices The following rules for safety wiring shall be observed, unless specific instructions to the contrary are given in the text:

•

Safety wire shall consist of two strands of wire twisted together (so-called doubletwist method), where one twist is defined as being produced by twisting the strands through an arc of 180×, equivalent to half a complete turn. Use the single-strand method only when specified.

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10-25

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-15. Safety-Wiring Practices (Sheet 1 of 2) 10-26

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 10-15. Safety-Wiring Practices (Sheet 2 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-27

GEK 105054 Volume I 10-4.15.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Safety Wire Installation

NOTE Apply light finger pressure at the midpoint of the safety wire span, and flex the wire in both directions to check for tautness.

The following safety-wiring procedures are to be used throughout the engine: CAUTION SAFETY WIRE SHOULD BE APPLIED SO THAT TENSION IS IN THE TIGHTENING DIRECTION, SO THAT ANY TENDENCY FOR A PART TO LOOSEN WILL BE COUNTERACTED BY THE SAFETY WIRE. FAILURE TO DO SO COULD RESULT IN PARTS COMING APART. a.

b.

c.

d.

Insert the safety wire through the first part and bend the upper end either over the head of the part or around it. If bent around it, the direction of wrap and twist of the strands shall be such that the loop around the part comes under the strand protruding from the hole. Done this way, the loop will not tend to slip upward and become slack. Twist the strands while taut until the twisted portion is just short of the nearest hole in the next part. The twisted portion should be within 1/8 inch (3.2 mm) of the hole in each part. If the free strand is to be bent around the head of the second part, insert the upper strand through the hole in this part, then repeat the previous step. If the free strand is to be bent over the unit, the direction of twist is unimportant. If there are more than two units in the series, repeat the preceding steps. After wiring the last part, continue twisting the wire to form a pigtail of three to eight twists (1/4 - 1/2 inch [6 - 13 mm] long) and cut off the excess wire. Bend the pigtail inward toward the part in such a manner as to prevent it from becoming a hazard to personnel.

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e.

If the safety wire is not taut after safetywiring per the preceding instructions, use the limits shown in Table 10-9 to determine its acceptability. Table 10-9. Installed Safety Wire Flex Limit

Length of Safety Wire Between Parts

Total Flexing at Center

in

mm

in

mm

1/2

12.7

1/8

3.2

1.0

25.4

1/4

6.4

2.0

50.8

3/8

9.5

3.0

76.2

1/2

12.7

4.0

101.6

3/4

19.1

5.0

127.0

3/4

19.1

6.0

152.4

3/4

19.1

f.

If the safety wire fails to meet the limits shown in Table 10-9, remove it and install new safety wire.

Always cut, rather than break, safety wire so that safety-wire holes are not torn or pulled out. Instructions for dismantling and disassembly do not include safety-wire removal because of the obvious necessity for removing safety wire.

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WARNING

GEK 105054 Volume I

•

The hand operated crimping tool operates in one direction only and has a cycle end dead stop to tell the operator when the ferrule is fully crimped. The crimping pressure of the tool is set by the manufacturer. If necessary, the crimping pressure can be adjusted with standard hand tools. The Snap-On tool has a spring loaded crimp rod to hold the ferrule in place during the crimping procedure. Cable tension is done automatically by the internal retraction mechanism.

•

Where possible, install the safety cable so it does not touch other parts.

•

Make sure the cable is not damaged or bent when installing safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted.

•

Install the safety cable through existing holes only.

•

Unless specified differently in the packager’s manual:

USE EXTREME CAUTION IN MONITORING THE SAFE AND COMPLETE REMOVAL OF ALL EXCESS SAFETY WIRE. CARE MUST BE TAKEN WHEN CUTTING OFF THE ENDS OF INSTALLED WIRE TO ENSURE COMPLETE RETRIEVAL IN ORDER TO PREVENT INJURY TO PERSONNEL AND/OR SUBSEQUENT ENGINE DAMAGE. When removing safety wire, ensure that all pieces are removed to prevent them from entering engine parts or otherwise causing damage. 10-4.16

Safety Cable

Safety cable is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens, it will not permit the fastener to part or turn. 10-4.16.1

Safety Cable General Practices

The safety cable system has three components: safety cable, ferrules and crimping tool.

•

•

The safety cable is available in one size, 0.032 inch (0.81 mm). One end of the cable will have a cable end fitting swaged to it. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying.

The maximum length of the safety cable between safety cabled parts is 6.0 inches (152.4 mm). No more than three bolts can be safetied with one safety cable. Safety cable shall not be used on titanium fasteners.

The ferrules are in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable.

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GEK 105054 Volume I 10-4.16.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Crimping Tool Verification

e.

Perform a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. GE Aircraft Engines recommends the pulloff load test be done at the beginning, middle, and end of each shift. Refer to manufacturer's instructions for pulloff load test procedure. 10-4.16.3 a.

Safety Cable Installation

CAUTION

Perform a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable.

DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL BREAK THE SAFETY CABLE.

NOTE Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. b.

Put the end of the cable without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part.

c.

Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, perform the same procedure for the third part.

f.

Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball.

g.

Hold the crimping tool perpendicular to the cable in the bolt head. Ensure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack.

h.

Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns).

i.

Pull up on the safety cable end to remove it from the tension block.

NOTE On a two bolt pattern, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull. d.

Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine.

10-30

Put the end of the safety cable through the crimping head of the crimping tool. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

j.

GEK 105054 Volume I

Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable.

k.

Cut the unused safety cable even with the crimped ferrule. Use the side cushioned cutters. Discard the unused safety cable.

l.

Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists.

m. Push against the safety cable with light finger pressure halfway between the safety cabled parts. If the cable feels loose, perform a dimensional check to ensure the safety cable is serviceable as follows (see Figure 10-16): (l)

(2)

(3)

Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A. Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C. Compare the dimensions that were written down to the limits given in Figure 10-16.

CAUTION DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS. n.

If the safety cable is not in the limits given in Figure 10-16, cut the safety cable with wire cutters and remove the installed safety cable. Install new safety cable.

10-4.17

Jackscrews

When using jackscrews to remove components, do not bend flanges or strip threads. Lubricate jackscrews with engine lube oil before installing. Turn jackscrews inward evenly and in small increments. Always check for and remove burrs or rough edges before using jackscrews. If regular bolts are used as jackscrews, the tips must be blunt and polished. Do not allow components to fall free as jackscrews are tightened. Jackscrew holes are often in flanges that are only thick enough for three or four threads. The ends of most standard bolts are chamfered, and the first couple of threads are missing or incomplete. These should not be used as jackscrews without modification, since only one or two threads will engage and the threads in the flange are likely to strip. Jackscrews, frequently designed as special tools and identified as such, are not chamfered and full thread engagement will occur. If specially manufactured jackscrews are not available and must be manufactured locally, be sure that the ends are ground to remove the chamfer and the incomplete thread so that the maximum number of threads may be engaged.

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GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-16. Safety Cable Flex Limits 10-32

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

10-4.18

Protective Closures and Caps

Preventing foreign material from lodging in drilled passages, fuel lines, oil lines, air lines, and open engine ports is extremely important. Machined surfaces must be properly protected to prevent damage. Do not remove plugs, caps, etc., until the part is ready for assembly. Check both seating surfaces for removal of plugs, etc. prior to assembly. Wrap precision parts and cap, or plug, all openings and connections. It is most important that all engine parts be kept clean and free of corrosion. All instructions that specify special handling of parts must be followed without exception. Accessories, tubes, and hoses may contain fuel or oil at the time of removal. Drain these fluids from the accessory being removed and cap all connecting hoses or tubes. 10-4.19

GEK 105054 Volume I

Hands and gloves must be clean when handling machined surfaces. After performing any maintenance, the work area shall be thoroughly inspected for loose parts, rags, tools, and other materials. The area shall be cleaned to remove grit, dust, chips, safety wire, and other small objects. 10-4.20

The following general instructions apply during unpacking and repacking to minimize possible part damage and contamination.

•

Initially, remove only that portion of the packing material necessary to mount the part. Where possible, remove the remainder of the packing material, including protective caps and plugs, one at a time as each connection (fluid, air, or electrical) is made.

•

Retain protective caps and plugs and reusable packing components for repacking purposes.

•

Install a cap or plug on each connection (fluid, air, or electrical) as it is disconnected.

•

When possible, repack the part for storage or shipment, using the same packing material in which the replacement part was received.

•

When original packing components are not available, use locally available packing materials and containers to pack the part. Make sure all ports, openings, connections, and mating surfaces are capped or covered and that the part is protected from potential handling or environmental damage.

•

Bearings shall be handled per paragraph 10-4.21 in this chapter.

Cleanliness

Cleanliness is important for equipment life and proper operation. One of the major causes of premature engine removal is foreign object damage (FOD). The enclosure must be kept clean and free of dirt and loose objects. It is recommended that small containers for foreign objects be kept in the work area or in tool boxes. All parts shall be inspected for cleanliness before being installed. Gaskets and preformed packings shall be free from dirt, lint, and/or grit. Mating flanges, tube flanges, and couplings shall be wiped clean to make sure that a good seal will be obtained.

Unpacking and Repacking

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GEK 105054 Volume I 10-4.21

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Bearing Handling

10-4.21.2

WARNING

CAUTION BALL AND ROLLER BEARINGS REQUIRE SPECIAL CARE TO PREVENT CORROSION. BEARINGS MUST NOT BE HANDLED WITH BARE HANDS NOR WITH ANY DEVICE THAT MIGHT CAUSE CONTAMINATION. CLEAN RUBBER OR NYLON GLOVES OR A PROTECTIVE HAND CREAM SHALL BE USED AT ALL TIMES WHEN HANDLING BEARINGS. 10-4.21.1

•

PRESERVATIVE OIL, MIL-C-6529, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED.

•

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT OR COLD PARTS. CAUTION

Preservation WARNING

•

IMMEDIATELY AFTER INSTALLING OR REMOVING A CHILLED BEARING, USE A HEAT GUN TO RESTORE THE BEARING AND ANY ADJACENT COLD AREA TO ROOM TEMPERATURE SO THAT CONDENSATION OF MOISTURE WILL BE MINIMIZED. CHECK CAREFULLY FOR EVIDENCE OF MOISTURE AND CONTINUE HEATING UNTIL THE BEARING IS COMPLETELY DRY. APPLY PRESERVATIVE OIL, MIL-C-6529, TYPE III, AT ONCE TO THE BEARING AFTER COMPLETE DRYING. FAILURE TO REMOVE MOISTURE COULD CAUSE CORROSION TO ACCUMULATE ON BEARING WHICH COULD RESULT IN BEARING FAILURE.

•

WHEN HEAT IS REQUIRED TO RELIEVE SHRINK FITS OF BEARINGS, USE HEAT GUNS OR OVENS. DO NOT USE DIRECT-HEAT SOURCES TO APPLY THE HEAT AND DO NOT HEAT THE BEARINGS TO A TEMPERATURE HIGHER THAN 350°F (176.6°C). APPLY PRESERVATIVE OIL, MIL-C-6529, TYPE III, TO THE BEARINGS BEFORE HEATING AND AFTER THEY HAVE COOLED TO ROOM TEMPERATURE.

PRESERVATIVE OIL, MIL-C-6529, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. At the point where bearings are accessible in the disassembly cycle, the bearings shall be thoroughly covered with preservative oil, MIL-C-6529, Type III. Use of engine lube oil as a lubricant or preservative is specifically prohibited. Personnel handling bearings must wear either synthetic rubber or nylon-mesh gloves with polyethylene palms and fingers. Bearings returned to storage shall be preserved with preservative, MIL-C-11796, Class 3, and wrapped in barrier paper, MIL-B-121, Grade A, Type I, Class 1, glossy side toward bearing. After installation, bearings shall be returned to room temperature and be preserved with preservative oil, MIL-C-6529.

10-34

Heating and Chilling

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

NOTE

CAUTION

Heating and chilling are defined as any temperature 10×F (6×C) or more above or below room temperature.

WHENEVER IT IS NECESSARY TO MARK ANY ENGINE PARTS, ONLY APPROVED MARKING COMPOUNDS SHALL BE USED. USE OF UNAUTHORIZED MARKING COMPOUNDS CAN CAUSE CORROSION WHICH CAN LEAD TO POSSIBLE PART FAILURE.

When it is necessary to chill a bearing in dry ice, the bearing shall be thoroughly coated with preservative oil, MIL-C-6529, Type III, and placed in a plastic bag prior to chilling. Immediately after installation of a chilled bearing, heat shall be applied with a heat gun until bearing and adjacent parts are brought to room temperature. Any moisture shall be removed using clean, dry shop air, and the bearing shall be protectively coated with preservative oil, MIL-C-6529, Type III. Heating of bearings shall be done using ovens or heat guns. No direct heat source, such as a blow torch, may be used. When the bearing returns to room temperature, it shall be protectively coated with preservative oil, MIL-C-6529, Type III. 10-4.22

Marking of Parts

Parts or assemblies designated as matched sets must be maintained as matched sets throughout maintenance activity. Set numbers, part numbers, and serial numbers shall be protected during cleaning or rework to prevent removal. When identification markings are removed or are no longer legible, the item must be re-marked per the appropriate marking method and at the location specified in the applicable Engine/Shop Manual or Service bulletin. There are two categories of marking: permanent and temporary.

Permanent marking of parts should be done in the area of lowest stress. Vibropeen is the acceptable method of permanent marking. Electric or chemical etch is not approved. CAUTION GREASE OR LEAD (GRAPHITE) PENCILS MUST NOT BE USED TO MARK COMBUSTION-SECTION OR HOT-SECTION PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE PARTS MATERIAL DAMAGE. Temporary marking is not intended to withstand engine operation and is normally removed during or following maintenance procedures. Lead- and sulfur-containing materials should not be used for marking any parts. Preferred materials are listed below:

•

Chalk

•

White paint marker

•

Dykem - red, yellow, black

•

Ink - Justrite Slink Black; Marco S-1141, black

•

March Stencil Ink

•

Sharpie - black

•

Sharpie - blue

•

Dixon - black

•

Dixon - yellow

•

Dykem Steel Blue DX100

•

Soapstone Change 1

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10-35

GEK 105054 Volume I 10-4.23

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Blending

•

NOTE Refer to specific engine manual section or service bulletin for blend limits for the piece part under review. Use the limits in this procedure only when no specific limits are specified for the component in the engine manual or appropriate service bulletin. Blending is a repair procedure that is used to remove stress concentrations caused by nicks, scratches, or other sharp-edged damage marks on critical parts. Removal of the material surrounding the stress concentration, so that the sharp edges are blended into smooth contour, relieves the stress concentration and permits further use of the part by lessening the danger of cracking.

10-4.23.2

Blending General Practices

WARNING PARTICLES FROM GRINDING OR SANDING ABRADABLE MATERIAL COULD BE HARMFUL TO EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY PROTECTION IS REQUIRED. NOTE Refer to the inspection and repair limits for specific instructions on blending limits applicable to each part of the engine. a.

When blending compressor rotor blades, stator vanes, turbine blades, and similar parts, blend in a radial direction in relation to the engine. Avoid removing metal from leading and trailing edges of airfoil sections in such a way that the edges become thin or sharp; blend so as to maintain approximately the original contour.

b.

When blending a cylindrical part, blend in a circumferential direction, not along the axis of the part.

c.

The finish on the blended area must be as close to the original finish as possible.

The following rules for blending shall be observed, unless specific instructions to the contrary are given in the text: CAUTION DO NOT REPAIR TITANIUM PARTS WITH TOOLS, SUCH AS GRINDING WHEELS, FILES, STONES OR EMERY CLOTH, THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DAMAGE TO PARENT METAL COULD OCCUR.

•

Hand Blending

Sharp edges can be blended out using abrasive stones or papers, files, or crocus cloth. Coarse grades of abrasives or files may be used for fast metal removal, but the parts must then be given a smooth surface finish with fine grades of abrasives or crocus cloth.

Blending is also used to remove sharp edges resulting from machining, drilling, etc., and to restore the original contour and/or surface finish to parts that have been repaired by welding, brazing, etc. 10-4.23.1

The finish on the blended area must be as close as possible to the original finish of the part.

Defects more than 0.25 inch (6.4 mm) apart shall be blended separately. Those less than 0.25 inch (6.4 mm) apart (except splines) shall be blended together. Splines that are closer together than 0.25 inch (6.4 mm) and defects shall be repaired separately.

10-36

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

d.

When blending on a part involving a radius, keep the radius as specified in the repair section. If the radius is not specified, keep it as close as possible to the original contour. Refer to a similar part, if necessary, to determine original radius.

e.

Etch reworked area per paragraph 10-4.24 and inspect by spot fluorescent-penetrant method, per paragraph 10-4.25, after blending

10-4.23.3

GEK 105054 Volume I

a.

Rough out defects using coarse grades of resilient flexible abrasive impregnated wheels, brushes, or points. Use fine or extra fine grades to finish the blend areas.

b.

Follow the requirements described in paragraph 10-4.23.2 when doing power blending.

c.

Etch reworked area per paragraph 10-4.24 and inspect by spot fluorescent-penetrant method, per paragraph 10-4.25, after blending.

Power Blending

Blending on most parts may be done by using a power-driven polishing wheel or rubberbonded abrasive points, and any special instructions for the individual part must be followed.

10-4.23.4 Component Specific Requirements NOTE Requirements in specific engine manual section or appropriate service bulletin take precedence over the following procedures. The requirements in this section should be used with engine manual or service bulletin criteria or when no criteria are specified.

WARNING PARTICLES FROM GRINDING OR SANDING ABRADABLE MATERIAL COULD BE HARMFUL TO EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY PROTECTION IS REQUIRED. CAUTION

•

POWER BLENDING OF AIRFOIL SECTIONS MAY BE DONE ONLY WHEN SPECIFIED BY INDIVIDUAL PART INSTRUCTIONS.

•

WHEN DOING POWER BLENDING, BE SURE TO AVOID BUILDING UP EXCESSIVE HEAT AND RESULTING THERMAL STRESSES IN THE PART.

a.

Blending Airfoils. (l)

The types of airfoil damage described below may be repaired by hand blending or by power blending. Always refer to applicable part inspection paragraph for a description of airfoil defect limits as follows: (a) Nick – A V-shaped depression in the airfoil made by a sharp-edge object pushing the metal inward. (b)

Pit – A round sharp-edged hole with a rounded bottom caused by corrosion.

(c)

Scratch – A V-shaped line or furrow in the airfoil such as would be made by dragging a sharp object across the surface.

NOTE After power blending of a titanium part is completed, hand blend the same area approximately 0.002 inch (0.05 mm) deeper to remove any residual stresses in the surface material.

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GEK 105054 Volume I

(2)

10-38

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

(d)

Dent – A smooth rounded depression in the airfoil made by impact with a rounded object. If there is any noticeable sharp discontinuity in the depression, it should be considered as a nick. Waviness of leading or trailing edge is to be treated as a dent.

(e)

Erosion – A sand- or shot-blasting effect on the leading edges or the leading portion of the concave side caused by sand or dust going through the engine.

(f)

Torn Metal – A separation or pulling apart of material by force, leaving jagged edges.

(c)

Defects more than 0.25 in (6.4 mm) apart shall be blended separately; those 0.25 in (6.4 mm) or less apart may be blended together. All blends must have a minimum radius of 0.25 in (6.4 mm). The total reduction in chord width may be taken on either side or divided between the sides. The amount of rework is controlled by the minimum chord width limit. The minimum allowable chord is given for root and tip of airfoil; the minimum chord at other points is proportional. To minimize the possibility of an engine stall, keep the shape of the blended airfoil leading edge as close as possible to the original contour (see Figure 10-17).

(d)

Blending limits are given as depth dimensions to make it easier to see how much can be repaired. Experience has shown that depth limits are used for most rework. However, the minimum chord limit is the most important dimension; it should be checked in borderline cases or where previous rework is evident in the same area. For convenience, the depth limits and minimum chord limits are given in both decimals and fractions. In borderline cases where depth limits and minimum chord limits conflict with one another, use the decimal minimum chord dimension to decide if the part is usable.

Hand-blending of airfoils may be done as specified below: (a)

Blending is done to remove stress caused by nicks, pits, and scratches to prevent blade failure. Remove high metal and straighten dents (where permitted) to restore the airfoil shape as closely as possible to its' original aerodynamic contour.

(b)

Blending shall be finished with fine stone or crocus cloth. Coarser tools may be used for initial removal of material. Finish blending in a direction along the length of the blade or vane and remove all evidence of marks across the airfoil that may have been made during initial blending.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 10-17. Airfoil Leading Edge Blending (e) Defect limits are given as depth dimensions since this is the dimension that affects strength. However, accurate depth measurements require special equipment not normally available. Comparing the depth of a defect with the thickness of a leaf of thickness gage or with the thickness of a piece of safety wire is a reasonably accurate way of measuring depth (see Figure 10-18).

(f)

(3)

Swab etch reworked area per paragraph 10-4.24 and spot-fluorescent-penetrant inspect per paragraph 10-4.25. Brush or swab on penetrant where air passages are present to prevent excessive penetrant entrapment.

Power-blending of rotor blades, variable vanes, and vane segments may be done as follows: (a) To avoid damaging the airfoil, use masking tape and mask off the airfoil next to the rework area.

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GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 10-18. Airfoil Defect Measurement (b)

Use coarse grade, silicon-carbide impregnated rubber wheels and points for the initial benching of the blades and vanes. NOTE

During finish blending of defects, make a radius on both the leading and trailing edges of the airfoil. To do this, apply light pressure with the rubberized abrasive wheel, and let the cushion action of the wheel do both the blending of the radius and the buffing of the defect. (c)

10-40

(d)

Swab etch reworked areas per paragraph 10-4.24 and spot-fluorescent-penetrant inspect per paragraph 10-4.25.

(e)

Place the repaired blades and vanes in separate containers to prevent damage during handling.

(f)

Carefully inspect the blades and vanes.

Finish blending the defects, using the fine and extra fine grade of rubberized abrasive wheels. Remove only enough material to repair the defect.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

b.

Blending Minor Indications in Tubing. (l)

(2)

c.

Use a fine abrasive stone, a small file, emery cloth, or crocus cloth for blending. Blend around the circumference of the tubing. The finished blend shall be as close as practical to the original finish of the part.

Removing High Metal. High metal is caused by the displacement of metal above a surface. It is found around defects like nicks and scratches. Remove high metal as follows:

GEK 105054 Volume I

(l)

Use a fine abrasive stone, a small file, emery cloth, or crocus cloth to remove high metal.

(2)

Remove only the material that is projecting above the original surface contour (see Figure 10-19).

(3)

Swab etch reworked area per paragraph 10-4.24 and spot-fluorescentpenetrant inspect per paragraph 10-4.25.

Figure 10-19. Blending and High Metal Removal

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Swab Etching Procedure

NOTE Keep fresh solution is contact with the metal surface at all times by dipping the swab into the working solution periodically. Rub the swab continuously over the surface of the metal being etched, to prevent the formation of an inert sludge.

This procedure describes the materials and process for swab etching used as a preliminary step before fluorescent-penetrant inspection. Etching solutions are used as described herein or with exceptions as specified for individual parts in the Shop Manual. WARNING ETCHING SOLUTION CONTAINS ACID AND IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION, AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT.

After etching, blot up etching solution from the metal surface with a clean paper towel or cloth.

e.

Gently wipe the etched area at least three times with a cloth or paper towel saturated with clean water. Blot dry with clean cloth or paper towel.

CAUTION

CAUTION

REFER TO THE MATERIAL SAFETY DATA SHEETS (MSDS) FOR STORAGE AND HANDLING INSTRUCTIONS FOR ETCHANT SOLUTION.

DO NOT POUR WORKING SOLUTION BACK INTO STOCK CONTAINER. ALTHOUGH THE SMALL QUANTITIES INVOLVED DO NOT ORDINARILY CONSTITUTE AN ENVIRONMENTAL HAZARD, FLUSH AWAY DISCARDED SOLUTIONS WITH SEVERAL VOLUMES OF WATER TO ENSURE ADEQUATE DILUTION.

a.

All surfaces to be etched must be free from oil, grease, scale, or other extraneous material.

b.

Pour a small quantity of stock solution into a clean plastic beaker or dish. This quantity will be the working solution, and is not to be returned to the stock bottle.

c.

d.

Saturate a cotton swab with the working solution, and swab the surface to be etched for 60 - 90 seconds, all Classes, except Class G. Class G etching time is 3 - 4 minutes. (Refer to MSDS for classification of etchant being used.). Keep the etching solution within defined boundaries of the area to be etched. Masking may be required to contain etchant to areas for etching.

10-42

f.

Discard used working solution, rinse, and dry plastic container for future use.

10-4.25 Spot-Fluorescent-Penetrant Inspection The spot-fluorescent-penetrant inspection process is intended for inspections at remote locations. It is a localized process, limited to small specific areas for inspection. It is not intended as a substitute for normal inspection. It is convenient to use for inspection of welded or other localized repair areas.

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Personnel performing this inspection must be certified in accordance with MIL-STD-410, American Society of Non- Destructive Testing (ASNT-TC-IA), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program.

(4)

White light lamp for visual inspection of parts.

(5)

Time piece for timing operations.

(6)

Tools for inspection personnel:

Any training which may be provided by GE for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with MIL-STD-410, ASNT-TC-IA, or ATA 105. 10-4.25.1 Spot-Fluorescent-Penetrant Inspection Equipment/ Materials a.

Equipment required: (1)

(2)

(3)

Inspection booth, darkroom, or black cloth hood (for remote locations) to prevent excessive admission of white light. Compressed air supply for drying parts. Air supply must have filters to remove oil and moisture which can contaminate parts or inspection materials. Ultraviolet lamp to detect fluorescent indications. The ultraviolet (black) light source used for the detection of fluorescent indications shall have an intensity no less than 1,000 microwatts per sq. centimeter when measured at 15 inches. (381.0 mm). The black light should be check on a weekly basis or before use, whichever is less frequent.

b.

(a)

Three power and 10 power magnifying lenses.

(b)

Cotton swabs or small fine hair art brush to apply solvents for evaluating questionable indications.

Materials required: NOTE Qualified Products listed in MIL-I-25135 QPL (Qualified Products List) as Level 3, Method D, are considered acceptable alternates to the products listed. (1)

Post-Emulsification Flourescent-Penetrant Oils: ZL22A, B, or C, ZL27 or ZL27A (Magnaflux Corporation)

(2)

Hydrophilic Removers: ZR10A or ZR10B (Magnaflux Corporation)

(3)

Dry Powders: ZP4A or ZP4B (Magnaflux Corporation)

(4)

Non-Aqueous Wet Developers (NAWD): ZP9B, C, E, F, or D499C (Magnaflux Corporation).

(5)

Halogen-free solvents: Isopropyl Alcohol (TT-I-735) or Acetone (O-A51)

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10-4.25.2 Spot-Fluorescent-Penetrant Inspection Procedure

OR DIGESTIVE SYSTEM. PERSONAL PROTECTIVE EQUIPMENT REQUIRED WHEN HANDLING OR USING THIS MATERIAL. MAY LEAD TO ALLERGIC SENSITIVITY IN SOME INDIVIDUALS. THERMAL DECOMPOSITION MAY RELEASE TOXIC BY-PRODUCTS. PROVIDE LOCAL EXHAUST OR GENERAL DILUTION VENTILATION TO MEET PUBLISHED EXPOSURE LIMITS. IF THESE ARE NOT AVAILABLE, USE RESPIRATOR HAVING NIOSH APPROVAL FOR THE MATERIALS RELEASED.

This procedure is to be used wherever the shop manual calls out specific classes using either waterwashable or post-emulsifiable penetrant systems. NOTE

•

If visible color dye penetrant has been used on parts which are to be subsequently inspected with fluorescent penetrants, the contamination by the dye may prevent reliable fluorescent penetrant inspection. Any color dye indications evident by white light visual inspection shall be considered valid indications even if not detectable by ultraviolet light.

•

CAUTION TITANIUM ALLOY PARTS ARE SUBJECT TO STRESS CORROSION CRACKING WHEN RESIDUES OF HALOGEN CONTAINING COMPOUNDS REMAIN ON A PART THAT IS SUBSEQUENTLY SUBJECTED TO ELEVATED TEMPERATURES TYPICAL OF WELDING, HEAT TREATING, OR ENGINE OPERATION. THESE PARTS MUST BE THOROUGHLY CLEANED WITH NONHALOGEN COMPOUNDS AFTER EXPOSURE TO ANY HALOGEN CONTAINING COMPOUND TO PREVENT THE CRACKING AND POSSIBLE FAILURE OF PARTS.

Excessive white light may interfere with detection of a rejectable size indication. A test part having a known defect can be used to evaluate effectiveness of white light shielding.

a.

Parts must be cleaned of all traces of oil, grease, carbon, and rust scale prior to penetrant application.

b.

Apply penetrant oil with soft-bristle brush, cotton swab, or spray application. Allow a minimum of 30 minutes for penetration.

NOTE Indications of defects can be lost by use of excessive solvent.

WARNING ACETONE, O-A51 AND ISOPROPYL ALCOHOL, TT-I-735 ARE EXPLOSIVE WHEN SUBJECTED TO HIGH TEMPERATURE, SOURCE OF IGNITION, HIGH PRESSURE, OR OTHER CHEMICALS. FLAMMABLE NEAR SPARKS, OPEN FLAMES, WELDING AREAS, HOT SURFACES, OTHER SOURCES OF IGNITION, OR WHILE SMOKING. INHALATION, CONTACT, OR INGESTION MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM, EYES, FACE, SKIN, 10-44

c.

Wipe off excess penetrant with a clean cloth using a solvent.

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(1)

Alternate. Remove excess penetrant with a hydrophilic remover provided it belongs to the same family as the penetrant used. Do not exceed 90 seconds contact time. If remover is applied manually, do not scrub the surface of the part with the applicator. Use applicator only to deliver fluid to the part surface. WARNING

NONAQUAEOUS DEVELOPER IS MIXED IN A SOLVENT BASE CONTAINING ACETONE, ISOPROPYL ALCOHOL, AND/OR TRICHLOROETHANE. SOLVENTS ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. AVOID BREATHING VAPORS AND USE IN A WELL-VENTILATED AREA. d.

Apply either dry powder or NAWD as a fine thin coating at ambient temperature to a dry surface. Allow a minimum of 10 minutes for developer to absorb penetrant before inspecting part.

e.

Evaluate any indication to the required inspection standards.

f.

Remove all residues by spraying, wiping, or soaking with approved solvents.

10-4.26 Miscellaneous Procedures CAUTION USE OF MOTOR-DRIVEN HYDRAULIC PUMPS TO OPERATE HYDRAULICALLY ACTUATED SPECIAL SUPPORT EQUIPMENT OTHER THAN TORQUE MULTIPLIERS IS NOT RECOMMENDED. EQUIPMENT DAMAGE CAN RESULT FROM IMPROPER POWER APPLICATION.

GEK 105054 Volume I

Use hand-operated hydraulic pumps to operate hydraulically actuated special support equipment such as pushers or pullers, unless otherwise specified. Exercise extreme care during assembly or disassembly operations to prevent entrance of pieces of safety wire, nuts, washers, or any other objects into the engine or assembly. If anything is dropped into the engine during assembly or disassembly, stop and remove the object before proceeding. Do not store tools or maintenance equipment on or against the engine. Account for and properly store all tools after use. Clean fittings of contamination before making or breaking connections. WARNING DO NOT USE EXTERNAL ENGINE PIPING AS A LADDER OR HANDHOLD WHILE PERFORMING MAINTENANCE. SERIOUS DAMAGE OR PERSONAL INJURY COULD RESULT. USE ONLY AUTHORIZED WORK STANDS AND PLATFORMS. CAUTION HANDLE ALL PARTS CAREFULLY. LIFT HEAVY PARTS WITH PROPER LIFTING FIXTURES AND A HOIST TO PREVENT DAMAGE TO PARTS AND PHYSICAL HARM TO PERSONNEL. Always use fiber or plastic blocks and hammers with plastic, rawhide, or nylon heads for driving operations.

Tie related parts together when removed. Tag or mark parts for identification. Change 1

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Coat parts to be stored for any length of time with an appropriate preservative.

WARNING

Verify identification of all mating parts.

PROLONGED EXPOSURE OF THE SKIN TO ENGINE LUBE OIL MAY BE DETRIMENTAL. WASH SKIN THOROUGHLY AFTER CONTACT AND REMOVE SATURATED CLOTHING IMMEDIATELY.

Observe tagged parts for proper location.

CAUTION

When installing or removing body-bound bolts, tap bolts straight through holes. Do not turn them.

During assembly, align matchmarks on all parts that were marked during disassembly. Keep all protectors, plugs, and caps installed until removal is required. Prior to final assembly, inspect all cavities and openings for foreign material. Inspect all mating flanges for foreign material prior to final assembly. Remove any high metal with a fine stone. CAUTION DO NOT MIX PLATED HARDWARE WITH UNPLATED HARDWARE. DO NOT USE SILVER OR CADMIUMPLATED TOOLS OR HARDWARE ON TITANIUM PARTS. PLATING CONTAINS SMALL QUANTITIES OF CHLORINE SALTS THAT ARE HARMFUL TO TITANIUM. Three types of tools (common, improvised, and special) are used to perform maintenance. Common tools are identified only when used in special applications. Drawings for improvised tools are incorporated in the text when such tools are required. Special tools are identified both by name and part number when required.

10-46

ENGINE LUBE OIL MAY SOFTEN PAINT OR STAIN CLOTHING. CLEAN SPILLED OIL FROM PAINTED SURFACES. Accessories, tubes, and hoses may have oil or fuel in them at time of removal. Drain these fluids from accessory being removed and cap all connecting hoses or tubes. Lubricate all gears and splines with engine lube oil before installation, unless otherwise specified. Prior to the installation of any part, a visual check should be made and any obvious signs of handling damage or abnormal wear should be noted and reported so that corrective action can be taken. Always read the complete operation and be sure you understand it fully. It is better to stop and ask than to continue and cause unnecessary work and/or damage. Do not disassemble any component any further than necessary to perform the required maintenance, even though complete disassembly instructions may be given. Remove piping and electrical leads only as required to perform maintenance tasks.

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Attaching hardware (bolts, nuts, plain washers, brackets, clamps, etc.) is generally reusable. When possible, it is recommended that attaching hardware be left in place or temporarily reinstalled until the replacement component is installed. Parts or assemblies designated as matched sets elsewhere in this manual or by the parts list shall be maintained as a matched set throughout the maintenance cycle. Set numbers, part numbers, and serial numbers shall be protected during cleaning or repair to prevent removal. When identification is removed, or is no longer legible, the item shall be remarked per the original marking method and location for the part. When discrepancies are found during maintenance, refer to inspection tables for limits and corrective action. NOTE Mobile Assembly Fluid 403C may be used in place of soft petrolatum. Petrolatum, GE Specification A50TF142, shall be used as an assembly aid for tight-fitting parts, bearings, and packing, unless otherwise specified. Ordinary petrolatum (VV-P-236) shall not be used.

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CHAPTER 11 Preventive Maintenance 11-1

PURPOSE AND SCOPE

This chapter defines the requirements and frequency for performing preventive maintenance checks, inspections, and servicing. Motoring procedures, generally associated with maintenance, are also provided, as are definitions of terms used to evaluate equipment condition and damage during inspections. 11-2

GENERAL CHECKS AND INSPECTIONS

This section provides general guidelines, conditions, and definitions for conducting engine checks and inspections.

In addition to the regular inspections, there are those necessary when the GG or GT has been operated outside of the specified limits, for example, off-schedule variable geometry operation, overspeed, or overtemperature. There are also special inspections necessary for GGs or GTs exposed to abnormal conditions. These may include, for example, failures with significant damage and other abnormal exposure such as an installation fire or mishap during transportation, handling, or storage. Some abnormal conditions to which an engine may be exposed are:

•

Shock loading, collision impact, exposure to explosion, handling, or transportation mishap.

•

Structural overstress, or mounting system overload to GG or power turbine (PT) interface (e.g., earthquake or installation error).

•

Any equipment failure where parts are not contained within GG or PT, or where a major rotating component separates.

11-2.1 Special Inspections

•

Sudden seizure or stoppage of GG or PT rotor or driven equipment rotors.

The maintenance of the gas generator (GG) or gas turbine (GT) requires that inspection checks be made periodically. The inspection requirements and limits throughout this manual are based on operation within specified limits.

•

Excess G-loading during operation in excess of packager manual limits.

•

Significant inlet ingestion events (e.g., foreign objects causing significant flowpath damage, ice ingestion, or inlet system failure).

Preventive maintenance, servicing inspections, and checks are performed to reduce unscheduled shutdown time. Table 11-1 lists the frequency of these inspections and checks to be completed on the LM2500+ SAC engine. If the frequency of inspection/service requires change, coordinate with the packager. For terminology and definitions, refer to Table 11-2. Tables presented at the end of section 11-4.

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GEK 105054 Volume I

•

Exposure to external fire, involving inlet system, exhaust system, base, enclosure, and equivalent.

•

Exposure to external fire in storage or transport.

•

Internal fire.

•

Thermal quench by water or other agent, or local overheating by fuel system failure.

•

Exposure to corrosive chemicals, fire-fighting agents, salt water, or sewage.

These events are highly variable and the exposure and associated damage which a GG or PT experiences is unpredictable. This prevents establishing a single, all-inclusive inspection and repair procedure. Depending upon circumstances of the event and instances of localization, limited damage can often be dispositioned by normal channels. For abnormal events, such as events listed above, execution of a special inspection workscope is necessary for proper restoration of serviceability. In some extreme cases, repair may not be possible or economical, and, therefore, further repair effort may not be advisable. Before proceeding with inspection and repair action to restore serviceability after a mishap, depot shall obtain service history of affected equipment and then contact the following for guidance: General Electric Company Marine & Industrial Engines Cincinnati, Ohio 45215-1988 USA ATTN: Customer Service Manager

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Assurance of a part’s serviceability is derived from control of material processing and manufacturing, operation within defined limits, and maintenance within defined limits and processes, as well as by inspection. Parts exposed to abnormal conditions may appear to be serviceable when in fact the actual state of the material cannot be ascertained even by the most advanced non-destructive testing and inspection methods. Parts which have been involved in an abnormal event shall be formally reviewed for severity of operation beyond normal working environment and dispositioned as to the necessity for a special inspection workscope. Since used replacement parts may be available which have operated in abnormal events, depot should verify that service histories of these parts are known and that, when applicable, required special inspections and part disposition following exposure to abnormal conditions have been completed and part is serviceable. Similarly, many components or assemblies from aircraft engines which have experienced previous flight service are not usable in LM engines. In addition, GT components which have experienced an extremely high number of start/stop cycles may not be usable. Specifically, use of used-serviceable flight or highcycle engine parts in the following categories is prohibited:

•

Rotating components.

•

Stator cases and stator vanes.

•

Frame assemblies, including sump components.

•

Main shaft bearings.

Prior to use of other components, contact General Electric (GE) Marine & Industrial Engines Customer Service about usability.

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GEK 105054 Volume I

MOTORING

11-4

Although not required as part of normal starting procedures, motoring is frequently used following maintenance to check the engine prior to making a start. Motoring is performed with the fuel shutoff valves closed. Refer to Chapter 7, paragraph 7-4.3 of this volume, for motoring procedure.

IDLE CHECKS

Idle power functional checks are usually performed following any maintenance on the engine, lube, or fuel systems that involve the breaking of connections, the separation of flanges, or any action that could possibly affect operation of the GT system. Refer to Chapter 7, paragraph 7-3.6.h of this volume, for idle check procedure.

Table 11-1. Preventive Maintenance and Servicing Checks Frequency Weekly (Note 1)

Maintenance Item

Semi-Annual (Note 2)

Reference

Enclosure Inspection

X

X

Packager’s Manual

Lube and Scavenge Pump Inlet Screens and Magnetic Chip Detector Inspection and Cleaning

X

X

WP 400 00

X

Packager’s Manual

X

Packager’s Manual

Inlet Inspection

X

WP 401 00

External Engine Cleaning

X

WP 402 00

External Engine Inspection

X

WP 403 00

Exhaust Inspection

X

WP 404 00

Gas Turbine starter oil return line Screen Inspection (if installed) Supply and Scavenge Lube filter Inspection

(See Note 5) (On Condition)

Compressor Cleaning

(On Condition)

X

WP 405 00

Borescope Inspection

(On Condition)

X

WP 406 00

X

WP 407 00

Lube Oil Sampling (Note 4) Hydraulic Pump Filter Inspection

(See Note 5)

X

WP 408 00

Igniter Check

(On Condition)

X

WP 409 00

Vibration Monitoring System Functional Check

(On Condition)

X

WP 410 00

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-1. Preventive Maintenance and Servicing Checks - (Cont.) Frequency Weekly (Note 1)

Maintenance Item

Semi-Annual (Note 2)

Reference

Overspeed Inspection

(On Condition)

WP 411 00

Overtemperature Inspection

(On Condition)

WP 412 00

Compressor Stall-Variable Stator Vane (VSV) Off-Schedule Inspection

(On Condition)

WP 414 00

Fuel System Inspection

X

WP 415 00

Thermocouple Inspection

X

WP 419 00

X

WP 417 00

High Pressure (HP) Recoup - Preferred Operating Range

(See Note 6)

Pneumatic Starter Servicing (Note 3) Variable Stator System Inspection

X X

X

WP 418 00

Redundant Overspeed System Check

X (See Note 8)

Packager’s Manual

Fabricated Thick Flange Turbine Mid Frame (TMF) (P/N L50533G01, G02) UT Inspection (See Note 9)

X

NOTES 1.

GE recommends certain preventive maintenance checks on a weekly basis; however, the user, for product efficiency purposes, may interpret this as a weekly or first opportunity thereafter frequency.

2.

GE recommends that semi-annual inspection interval not be exceeded on any items. Semi-annual inspections shall be made with engine shut down.

3.

An initial fill with 350 - 450 cm3 of lube oil is required before first operation. Refer to WP 122 00, Volume II, for specific instructions. GE supplied pneumatic starters are of a continuous lube type and no additional servicing is required. For other types of starters, consult the packager manual.

4.

Lube oil should be sampled at every engine changeout, periodic engine shutdowns, and maintenance, with a minimum monthly rate.

5.

Lube and hydraulic pump filters should be inspected whenever the differential pressure drop increases by 100 percent from clean condition.

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Table 11-1. Preventive Maintenance and Servicing Checks - (Cont) Frequency Weekly (Note 1)

Maintenance Item

Semi-Annual (Note 2)

Reference

6.

HP recoup pressure check intervals: a. For engines with less than 500 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at 100 hours intervals (up to 500 hours) per WP 417 00. b. For engines with over 500 hours but less than 2,000 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at 500 hours intervals (up to 2,000 hours) per WP 417 00. c. For engines with over 2,000 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at semiannual intervals per WP 417 00.

7.

PT thrust balance cavity pressure check intervals: Use same intervals as listed above for HP recoup pressure check. Adjust PT thrust balance cavity pressure per Volume II, WP 431 00.

8.

Semi-annually test the redundant overspeed protection system to verify it’s function using a simulated speed signal input.

9.

A certified ultrasonic inspector, with Level II or higher certification, should perform this UT inspection. Part-specific training required. Table 11-2. Definition of Terms Manual Terms

Associated Terms

Abrasion Wearing, grinding, or rubbing away of small amounts of material. Surface may be smooth or rough

Chafing, Fretting, Rub, Scuff, Wear

Blister A raised portion of a surface caused by separation of the outer layers of the parent material or of a coating

Bubble, Flaking, Oxide formation, Peeling, Scale, Slag inclusion (Weld)

Brinell (True) Often related to ball and roller bearings having been improperly installed or subjected to extremely high shock or impact loads at zero revolutions per minute. Usually occurs as a series of shallow depressions in the load area of the raceway

Dent

Brinell (False) A specialized form of fretting recognized by the occurrence of a series of shallow indentations in the race at each roller position on the loaded side of the bearing. Often red oxide of iron may be found where this has occurred 11-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Brittle A change in the resiliency of the parent material, usually due to aging, extreme heat, extreme cold, chemical action, or cold-working (metal)

Cold-worked, Hard (like an old packing), Stiff

Buckle A large-scale deformation of the original contour of a part, usually due to pressure or impact from a foreign object, structural stresses, excessive localized heating, high pressure differentials, or a combination of these

Ballooning, Bend, Blister (incorrect see Blister), Bulge, Crease, Curl, Dent (not to be confused with small area defect in heavy material [see Dent]), Depression, Distortion (usually refers to heavy material), Elongated (usually refers to outs of round), Fold, Indentation, Kink (usually results in crack: see Crack), Protrusion (hollow), Rupture (result of excessive buckling), Uneven, Warpage, Wrinkle

Bulge A raised portion or outward swelling on a surface, as from pressure

Hump, Protuberance

Burn A rapid, destructive, oxidizing action usually caused by higher temperatures than the parent material can structurally withstand. Change in color and appearance often indicates this condition

Burnout (see Missing piece), Erosion (chemical or grit), Guttered, Heatcheck, Heat curled, Heat deterioration, Hole (burn), Hot spot, Overheated, Oxidation

Burr A rough edge or a sharp edge on the surface of the parent material Chafing A rubbing action between parts having limited relative motion (as in vibration)

Abrasion, Fretting, Rub, Wear

Chip A breaking away of the edge of the parent material, usually caused by heavy impact from a foreign object

Break, Nick (similar to Chip, but no parent material is removed [see Nick])

Coking An accumulation of carbon

Carbon buildup

Corrosion The gradual conversion of material to another compound due to chemical attack. It appears as a mass of small pits due to the loss of the formed compound from the affected surface which cumulatively creates a cavity (usually shallow) in the surface of the parent material

Sulfidation

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Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Crack A parting of the parent material

Break, Crater (usually found in castings), Fatigue damage, Fissure, Fracture, Inclusion (usually found in castings), Lap (usually found in forging), Rupture, Separation, Shear (not usually considered a crack: see Missing Piece), Slit, Tear

Craze A mesh of fine cracks on a surface or glaze defined as numerous superficial surface cracks which have no significant width or depth

Fine cracks around bolt holes or surface edges that are subject to stresses or pressure. Fine cracks in metal, paint surfaces, seal edges, plastics, windows, sight glasses, coatings, etc.

Dent A completely smooth surface depression caused by pressure or impact from a smooth, balllike foreign object. Parent material is displaced, but usually none is separated

Peen

Deviation A condition which causes a port to differ from the manufacturer's blueprint

Damage, Defect, Flow, Imperfection, Irregularity

Erosion The gradual wearing away of material caused by the hot flow of gases or foreign particles. An eroded surface may appear similar to a corroded surface Flake A thin, chip-like or scale-like layer of metal Fretting Wear, in a rippled pattern, caused by friction

Chafing, Abrasion

Gall A defect caused by the movement of two surfaces in contact with each other. In most cases an accumulation of foreign material is deposited on the parent material

See Pickup

Gouge A wide, rough scratch or group of scratches, usually with one or more sharply impressed corners and frequently accompanied by deformation or removal of parent material

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-2. Definition of Terms - (Cont.) Manual Terms

Groove A long, narrow, continuous cavity or impression caused by pressure of a moving surface in contact with the parent material

Associated Terms If impression is shallow and smooth, see Wear

Imbalance The state of being out of balance. An unequal distribution of weight about the axis of rotation Loose Abnormal movement of a part

Backed out, Excessive movement, Excessive play, Insecure, Leaks, Loose fit, Not tight, Not torqued, Shakes, Sloppy, Rattles, Unbuttoned, Unpinned

Misaligned Mismatch or malformation of any part that either prevents perfect assembly or results in faulty operation and/or ultimate part failure

Eccentric, Not axial, Not concentric, Out-of-round, Unmatched, Unsquare

Missing Piece Removal or loss of a portion of parent material due to a combination of defects or damage

Break (two or more pieces), Burn (burned away), Burnout, Corrosion (eaten away), Erosion (worn away), Guttered, Hole, Rusted (rusted away), Sheared, Smashed, Torn (torn away)

Nick A surface impression with sharp comers or bottom, usually caused by pressure or impact from a sharp-edged foreign body. Parent material is displaced, but usually none is separated

Chip (see Chip), Dent (see Dent), Notch (see Chip)

Noisy An abnormal sound condition of moving parts, usually an increase in volume or a change of pitch

Bumps (sound), Chatters, Clicks, Grates (usually gears), Grind, Hums, Loud, Rattles (usually loose parts), Rubs (sound of rubbing), Scrapes (sound of scraping), Screeches, Squeals, Thumps (sound), Whistles

Obstructed Prevention of free flow of a fluid (air, oil, fuel, water) because of foreign material in the flowpath or malformation in the flow member

Clogged, Contaminated, Plugged, Restricted

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Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Oxidation A surface deterioration by the chemical reaction between oxygen in the air and the metal surface. Attack is manifested as red rust in iron and low alloy steels when formed at ambient temperature. Oxides which form on super alloys are complex and can be green or black depending on material composition and the temperature at which it is formed

Burn, Rust

Pickup Transfer of one material into or upon the surface of another, caused by contact between moving parts or deposits of molten material on a cooler material

Burr (usually tool-tub leaving high parent material), Gall, High spot, Imbedment, Inclusion (usually pick-up of a dissimilar foreign material), Pileup, Protrusion (deposit on parent material), Metallization

Pinched Distortion of one or more surfaces of the parent material, caused by pressure

Bound, Compressed, Flattened, Seized (see Seizure), Smashed (without separation into pieces), Squashed, Squeezed, Tight

Pit A minute depression or cavity with no sharp, high-stress comers in the surface of the material. Pits are usually caused by chemical reaction (rusting and chemical corrosion)

Corrosion, Crater (usually in weld or casting), Dent (incorrect: see Dent), Electrolytic cavity, Erosion (usually results in hole: see Burns), Fretting (see Wear), Inclusion (as in sand castings), Oxidation (usually in weld), Pock-marked, Spalled, Roughness

Rub A surface cavity or impression caused by two surfaces moving against each other

If impression is shallow and smooth, see Wear. If impression is sharp, see Scratch

Scratch A long, narrow, sharp-cornered impression caused by the movement of a sharp object across the surface of the parent material

Abrasion, Chafe, Furrow, Groove, Rub, Scarf, Score

Scuff A surface roughened by wear

Scrape, Scratch

Seizure A welding or binding of two surfaces that prevents further movement

Bound up, Frozen, Tight (see Pinched), Tight (fit), Wedged, Welded (without external assistance)

Sheet-Metal Dent A large-area, smooth depression in the parent material

See Buckle

11-9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Shingling Two adjacent surfaces overlapping when normal position is edge-to-edge or face-to-face contact Spall Broken or crushed material due to heat, mechanical, or structural causes. Chipping of small fragments under the action of abrasion

Chip

Spatter A thin deposit of molten metal, usually on airfoil surface downstream from a burn area or coating deposit

Splatter, Splash

Sulfidation A form of hot corrosion in heat-resistant alloys by the reaction at the metal surface of sodium chloride (sea air) and sulfur (from fuel). Attack usually occurs over a broad front and can be identified as gray to black blisters (early stage) or surface delamination (advanced stages)

Hot corrosion

11-10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

CHAPTER 12 Critical Parts Life Management for LM2500+ Industrial Gas Turbines 12-1 INTRODUCTION

b

Critical life-limited parts are those parts whose sudden failure could threaten the structural integrity of the engine or its package. Stress cycles on gas turbine parts result from transients of speed and temperature that occur during starts, accelerations, and decelerations. Therefore, life limits are expressed in terms of engine cycles and can be related to normal operational data.

c.

Cycles are defined in paragraph 12-2, DEFINITIONS. Life limits of critical parts are established through analysis and testing. Accumulated cycles are to be calculated, tracked, and compared to published declared life limits to determine when a part should be permanently retired from service. No component shall be allowed to remain in service beyond its published life limit in any application. Paragraph 12-5 defines how cycles are to be calculated.

d.

GE critical life-limited parts have undergone extensive analysis which provides a basis for establishing the life limits defined in Table 12-1. GE will continue evaluating component life limits and will revise this chapter when life limit changes can be technically justified.

e.

The critical parts life limitations have been substantiated based on engineering analysis that assumes this product will be operated and maintained using the procedures and inspections provided in the instructions for continued operation supplied with this product by GE, or its licensees. For Life Limited Parts and parts that influence Life Limited Parts, any repair, modification or maintenance procedures not approved by GE, or its licensees, or any substitution of such parts not supplied by GE, or its licensees, may materially affect these limits.

CAUTION

•

CRITICAL LIFE-LIMITED PARTS MUST BE REMOVED FROM SERVICE BEFORE REACHING THEIR DECLARED LIFE LIMIT.

•

UNDER NO CIRCUMSTANCES SHALL ANY PREVIOUSLY USED CRITICAL LIFE-LIMITED PART BE INSTALLED INTO A LM2500+ GAS TURBINE OR GAS GENERATOR WITHOUT DOCUMENTED KNOWLEDGE OF PAST CYCLIC OPERATIONAL HISTORY OF THE PART.

•

•

a.

NO PART PREVIOUSLY OPERATED IN A NON-COMMERCIAL MARINE GAS TURBINE OR GAS GENERATOR SHALL BE INSTALLED INTO A COMMERCIAL MARINE GAS TURBINE. SERIOUS ENGINE DAMAGE CAN OCCUR IF ALL PROVISIONS OF THIS CAUTION ARE NOT COMPLIED WITH. This chapter identifies specific parts of the LM2500+ industrial gas turbine that are cyclic life-limited as a result of exposure to normal operating conditions. This chapter provides instructions for tracking the operating hours and operating cycles for such parts that have been identified by GE as being limited in terms of operating service life.

12-1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I 12-2 DEFINITIONS a.

b.

c.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 12-3 AFFECTED PARTS

Full Cycle: A full cycle is defined as an engine start from zero gas generator speed to high power (greater than 8,000 RPM), followed by a shutdown of the gas turbine. Partial Cycle: A partial cycle is defined as a decrease from high power (greater than 8,000 RPM) to gas generator idle (less than 6,800 RPM), followed by an increase to high power (greater than 8,000 RPM). Trip (or stop-cock) cycle: A trip or stopcock cycle is defined as a cycle from zero gas generator speed, with acceleration to high power setting (any power setting above idle), followed by a rapid (uncontrolled) shutdown.

d.

Declared Life: Declared life is the cyclic life limit of a critical life-limited part.

e.

Accumulated Cycles: Accumulated cycles represent the calculated life consumed by a part, considering full, partial, and trip cycles seen by the part during operation.

CAUTION CRITICAL LIFE-LIMITED PARTS SHALL NOT BE OPERATED BEYOND THE PUBLISHED DECLARED LIFE LIMITS. SEVERE ENGINE DAMAGE COULD RESULT FROM FAILURE TO COMPLY. The critical life-limited parts for the LM2500+ Industrial Engine are listed in Table 12-1. 12-4 PARAMETERS TO BE TRACKED a.

Engine operating hours and cycles must be recorded and tracked for each critical lifelimited part. Each part is uniquely identified by the combination of its part number and serial number. Parameters to be tracked are shown in the Critical Parts Tracking System Data Sheet shown in Figure 12-1. A data sheet must be created and maintained for each critical part throughout its entire life. CAUTION IT IS THE OWNER’S/USER’S RESPONSIBILITY TO ESTABLISH A TRACKING SYSTEM TO ENSURE THAT ADEQUATE RECORDS ARE MAINTAINED FOR EACH CRITICAL LIFE-LIMITED PART AND THAT NO SUCH PART EXCEEDS ITS LIFE LIMIT.

b.

When any critical life-limited part is transferred from one location to another or used as a rotable spare, this event must be recorded on the Critical Parts Tracking System Data Sheet for that part. The data sheet, containing the life history record of a critical life-limited part, maintains documentation of the part’s cyclic life history as the part transfers from one location to another.

12-2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I The coefficients Kf, Kp, and Ksc are listed for each component in Table 12-1. A part shall be permanently removed from service prior to the accumulated cycles reaching the declared life limit of the component listed in Table 12-1.

12-5 CALCULATING ACCUMULATED CYCLES AND RECORDING DATA a.

As defined in paragraph 12-2, a cycle may be designated as a full, partial, and trip cycle. In order to take credit in most cases for the increased capability of a partial cycle, the life consumed is calculated by considering full, partial, and trip cycles. The consumed life of the part is designated as the accumulated cycles on the part. Accumulated cycles are calculated using the following equation:

b.

Accumulated Cycles = Kf x (Full Cycles) + Kp x (Partial Cycles) + Ksc x (Trip or Stop-cock Cycles)

The owner/user is responsible for the maintenance of accurate records of all engine hours and cycles. The owner/user should monitor status of the parts to ensure that none listed in Table 12-1 exceed the declared life limits published in this chapter.

c.

The owner/user is responsible for documenting the history of critical life-limited parts in such a way as to make possible a historic record between part numbers and serial numbers and their respective assembly and/or engine.

Table 12-1 Declared Life Limits for the LM2500 Plus Engine Module

Component

Part Number

Industrial Declared Life Kf Limits

Kp

Ksc

Stage 0 Blisk

K070P02

17,800

1.0

N/A

N/A

Stage 1 Disk

L50507P01-P02

3,800

1.0

N/A

N/A

Stage 1 Disk

L50507P03

14,000

1.0

N/A

N/A

Stage 1-2 Spacer

L50588P01-P03

5,200

1.0

N/A

N/A

Stage 1-2 Spacer

L50588P04

4,900

1.0

N/A

N/A

Stage 2 Disk

L44742P01

6,100

1.0

N/A

N/A

Stage 2 Disk

L50508P01-P02

5,400

1.0

N/A

N/A

Stage 3-9 Spool

9021M64P13-P14 10,100

1.0

N/A

N/A

Stage 10-13 Spool

L50509G01-G04

7,800

1.0

N/A

N/A

Stage 14-16 Spool

L50510P01

4,900

1.0

N/A

N/A

Stage 14-16 Spool

L50510P03

7,200

1.0

N/A

N/A

Stage 14-16 Spool

L50510P04

5,800

1.0

N/A

N/A

CDP Seal

L50513P01

12,900

1.0

N/A

N/A

CDP Support

L50514P01

20,000

1.0

N/A

N/A

HPCR

12-3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Table 12-1 Declared Life Limits for the LM2500 Plus Engine (Continued) Module

Component

Part Number

Industrial Declared Life Kf Limits

Fwd Shaft

9208M79P09

6,600

1.0

N/A

N/A

Stage 1 Disk

L47518P01

12,100

1.0

N/A

N/A

Stage 2 Disk

L47520P01

5,300

1.0

N/A

N/A

Spacer

L47519P04

5,900

1.0

N/A

N/A

Rear Shaft

L31304P03

5,600

1.0

N/A

N/A

Stage 1 Disk

L50501P02

TBD

1.0

N/A

N/A

Stage 2 Disk

L50502P02

TBD

1.0

N/A

N/A

Stage 3 Disk

L50503P01

TBD

1.0

N/A

N/A

Stage 4 Disk

L50504P01

TBD

1.0

N/A

N/A

Stage 5 Disk

L50505P01

TBD

1.0

N/A

N/A

Stage 6 Disk

L50506P01

TBD

1.0

N/A

N/A

Fwd Shaft

L21497P08

TBD

1.0

N/A

N/A

Aft Shaft

L50525P02

TBD

1.0

N/A

N/A

BP Seal

L16742P02

TBD

1.0

N/A

N/A

BP Support

L14475P02

TBD

1.0

N/A

N/A

Kp

Ksc

HPTR

LPTR

12-4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

Figure 12-1 Critical Parts Tracking System Data Sheet Example

12-5/(12-6 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

APPENDIX A Gas and Liquid Fuel, Water, Steam, and Detergent Requirements This appendix contains specifications for the following: A1

Natural Gas Fuel

A2

Liquid Fuel

A3

Water Purity - NOx Suppression

A4

Water Purity - Compressor Cleaning

A5

Liquid Detergent - Compressor Cleaning

A6

Lubricating Oil

A-1/(A-2 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

MID-TD-0000-1 September 2009

5

MID-TD-0000-1November 2001

Appendix A1 Fuel Gases for Combustion in GE AeroDerivative Gas Turbines GE AeroDerivative gas turbines have the ability to burn a wide range of gaseous fuels, as shown in Table A1-1. These gases present a broad spectrum of properties due to both active and inert components. This specification is designed to define guidelines that must be followed in order to burn these fuels in an efficient, trouble-free manner, while protecting the gas turbine and supporting hardware.

A1-1 Applicable Documents Table A1-2a identifies the fuel composition limits for aeroderivative gas turbines with Dry Low Emission (DLE) combustion systems and Table A1-2b identifies the fuel composition limits for aeroderivative gas turbines with Standard (Single Annular Combustor [SAC]) combustion systems. Table A1-3 identifies the acceptable test methods to be used in determining gas fuel properties.

2. Values and limits apply at the inlet of the gas fuel control module. 3. Heating value ranges shown are provided as guidelines. Specific fuel analysis must be furnished to GE for evaluation. The standard configured single annular combustor (SAC) gas turbines require a fuel with a Low Heating Value (LHV) no less than of 6500 Btu/pound. The Dry Low Emissions (DLE) combustion system requires a minimum LHV of 18,000 Btu/pound. (Reference Section A1-3.1) 4. The fuel gas supply shall be 100% free of liquids. Admission of liquids can result in combustion and/or hot gas path component damage. (Reference Section A1-3.3) 5. Modified Wobbe Index (MWI), is described in Section A1-3.2.

The following should be noted and apply to Tables A1-1, A1-2a, and A1-2b: 1. When considering the use of alternate fuels, provide details of the fuel constituents, fuel pressure, fuel temperature, and expected engine usage conditions and operating characteristics to GE for evaluation and recommendations.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

A-3

MID-TD-0000-1 September 2009

Table A1-1. Fuel Classification LHV Btu/scf

Major Components

Pipeline Natural Gas and Liquefied Natural Gas

800 - 1200

Methane

Liquefied Petroleum Gas

2300 - 3200

Propane, Butane

- Air Blown

100 - 150

Carbon Monoxide, Hydrogen, Nitrogen, Water Vapor

- Oxygen Blown

200 - 400

Carbon Monoxide, Hydrogen, Water Vapor

300 - 3000

Methane, Hydrogen, Carbon Monoxide, Ethane, Ethene, Propane, Propene, Carbon Dioxide, Nitrogen

Fuel

Gasification Gases

Process Gases

Table A1-2a. Fuel Gas Composition Limits for DLE Configuration Parameter

Requirements - DLE Configuration Minimum

Maximum

40 (See Note 2)

60

50% Vol

100% Vol

LM1600

0

35% Vol

LM2500 / LM2000

0

35% Vol

LM2500+G4

0

30% Vol

LM6000 / LMS100

0

24% Vol

Hydrogen (H2)

0

5% Vol (See Note 2)

Diolefins (i.e. Butadiene, Propadiene)

0

None allowed

Other combustibles (See Note 3)

0

Consult GE

Modified Wobbe Index (See Note 1) Methane (CH4) Ethane (C2+ paraffins)

Notes: 1.

MWI at max limits C2+.

2.

Other levels may be possible. Consult GE.

3.

Other combustibles - CO, olefin hydrocarbons, etc.

A-4

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

MID-TD-0000-1 September 2009 Table A1-2b. Fuel Gas Composition Limits for SAC Configuration Parameter

Requirements - SAC Configuration Minimum

Maximum

LMS100 Low MWI Nozzles

35

44

LMS100 Standard MWI Nozzles

45

60

All Other LM

40

60

LM2500 / LM2000

0

85% Vol

LM2500+ / +G4 / LM1600 / LM5000

0

75% Vol

LM6000 / LMS100

0

35% Vol

Diolefins (i.e. Butadiene, Propadiene)

0

See Note 3

Olefins

0

15% Vol (See Note 4)

Other combustibles (See Note 5)

0

Consult GE

Modified Wobbe Index (See Note 1)

Hydrogen + 1/2 CO (H2 + 1/2 CO) (See Note 2)

Notes: 1.

Expanded values may be possible with fuel nozzle modifications. Consult GE.

2.

High hydrogen and carbon monoxide content fuels have large rich to lean flammability limits. These types of fuels often require inert gas purging of the gas turbine gas fuel system upon unit shutdown or a transfer to a more conventional fuel. When process gas fuels have extreme flammability limits such that the fuel will auto ignite at turbine exhaust conditions, a more “conventional” start-up fuel, such as methane, is required.

3.

The presence of even trace amounts of butadiene in the gas fuel may cause fuel system fouling. Additional fuel system maintenance may be required when using fuels containing butadiene.

4.

Olefins in the gas fuel at moderate levels (100

Count (per 100 ml sample)

Visual

1,000 PPM per 10 ml sample

5.

Water

10,000 1500 200 20

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 407 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. SOAP Analysis Element 1.

2.

Normal Range

Monitor Range (On-Watch)

Shutdown Level

Iron (Fe)

0-3

4-7

8+

Silver (Ag)

0-1

2-4

5+

Aluminum (Al)

0-1

2-4

5+

Chromium (Cr)

0-4

5-7

8+

Copper (Cu)

0-5

6-10

11+

Magnesium (Mg)

0-1

2-4

5+

Nickel (Ni)

0-3

4-6

7+

Silicon (Si)

0-20

21-36

37+

Titanium (Ti)

0-3

4-6

7+

Molybdenum (Mo)

0-3

4-6

7+

Lead (Pb)

0-3

4-6

7+

Tin (Sn)

0-15

10-22

23+

Zinc (Zn)

0-10

11-17

18+

Iron (Fe)

0-8

9-13

14+

Silver (Ag)

0-3

4-6

7+

Aluminum (Al)

0-3

4-6

7+

Chromium (Cr)

0-6

7-9

10+

Copper (Cu)

0-12

13-19

20+

Magnesium (Mg)

0-6

7-9

10+

Nickel (Ni)

0-5

6-8

9+

Silicon (Si)

0-25

26-64

65+

Titanium (Ti)

0-5

6-8

9+

Molybdenum (Mo)

0-5

6-8

9+

Lead (Pb)

0-2

3-4

5+

Tin (Sn)

0-20

21-39

40+

Zinc (Zn)

0-15

16-22

23+

Atomic Absorption Method

Atomic Emission Method

5/(6 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 408 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HYDRAULIC PUMP FILTER ELEMENT INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 3 ................... 0 4 Blank ............. 0 Alphabetical Index Page

Subject Hydraulic Pump Filter Element Inspection. .....................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 408 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for inspection of the hydraulic pump filter element.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Hydraulic Filter Housing and Element Replacement Illustrated Parts Breakdown

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 122 00 GEK 105055

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Hydraulic Filter Element Gasket

55-46 55-45

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 408 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Hydraulic Pump Filter Element Inspection. a.

Comply with all instructions contained in WP 002 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Remove hydraulic pump filter element from housing per WP 122 00.

c.

Inspect filter bowl for large particles.

d.

Inspect filter element for contaminants.

e.

If contaminants are found, perform following steps: (1)

If found during periodic inspection, replace filter.

(2)

If found due to variable stator vane (VSV) low pressure alarm, check hydraulic pump for failure.

f.

Install hydraulic pump filter element into housing per WP 122 00.

g.

Motor engine per GEK 105054, Chapter 7, and check for leaks.

3/(4 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 409 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES IGNITION SYSTEM FUNCTIONAL CHECK (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 ................... 0 Alphabetical Index Page

Subject Ignition System Functional Check. ....................................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 409 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for a functional check of the ignition system.

2.

Reference Material. Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Troubleshooting Operation and Maintenance Manual, Volume II General Maintenance Practices Ignition Exciter Replacement

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

GEK 105054 Chapter 7 Chapter 10 GEK 105054 WP 002 00 WP 104 00

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 409 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Ignition System Functional Check. a.

Prior to inspecting ignition system, perform following: (1)

Comply with all instructions contained in WP 002 00.

(2)

Shut off electrical power to ignition system. Tag ignition system electrical power out of service.

(3)

Clear combustor of any residual fuel as follows: (a) Motor engine per GEK 105054, Chapter 7, for 1 minute. (b) Allow engine to coast down and stop rotation. WARNING

IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE. b.

If two igniter plugs are installed, check igniter operation as follows: (1)

Check 4:00 o’clock position igniter plug operation as follows: (a) Disconnect, at ignition exciter, electrical lead of igniter plug not being checked per WP 104 00. (b) Temporarily secure electrical lead of igniter plug not being checked away from ignition exciter. (c) Reapply power to ignition system per packager’s manual. Igniter plug shall energize. (d) Listen for audible cracking when igniter plug fires. (e) Remove power from ignition system per packager’s manual. (f) Reconnect, at ignition exciter, electrical lead of igniter plug not being checked per WP 104 00.

(2) c.

Repeat steps (a) through (f) for igniter plug at 5:00 o’clock position.

If single igniter plug is installed, perform steps b.(1)(c) through (e).

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 409 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

d.

If cracking noise is not heard when testing igniter plug(s), check out system to isolate problem. Take appropriate corrective action per GEK 105054, Chapter 10.

e.

Remove tag and restore electrical power to ignition system per packager’s manual.

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 410 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES VIBRATION MONITORING SYSTEM FUNCTIONAL CHECK (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 3 ................... 0 4 Blank ............. 0 Alphabetical Index Page

Subject Vibration Monitoring System Functional Check...............................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 410 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for a functional check of the vibration monitoring system installed on LM2500+ Models GK and GV gas generators and Model PK gas turbine. For LM2500+ Model PV gas turbine, consult GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Accelerometer Replacement WP 111 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment. Nomenclature

Part No.

Multimeter

Local Purchase

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 410 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Vibration Monitoring System Functional Check. a.

Comply with all instructions contained in WP 002 00. NOTE

b.

c.

•

Gas generators have accelerometer located on compressor rear frame (CRF) forward flange.

•

Gas turbines with six stage power turbine have accelerometers mounted on CRF forward flange and turbine rear frame (TRF) forward flange.

•

For gas turbines with two stage high speed power turbine, consult GEK 105052 for power turbine accelerometer placement.

Perform mechanical inspection of accelerometer as follows: (1)

Inspect accelerometer(s) for physical damage. Replace as required.

(2)

Inspect accelerometer(s) mounting hardware for proper installation. If loose, reinstall per WP 111 00.

(3)

Inspect accelerometer(s) electrical leads for proper installation. If loose, reinstall mounting hardware per WP 111 00.

(4)

Inspect security of accelerometer electrical connectors to packager leads per packager’s manual.

Check accelerometer(s) for continuity and isolation as follows: NOTE Electrical problems are evident by erratic or no output from transducer, and are indicative of contaminated connector contacts, loose connector, or damaged leads at connector backshell. (1)

Using multimeter, check continuity between connector pins. Resistance shall be 1,000 megohm, minimum.

(2)

Using multimeter, check isolation between accelerometer case and each connector pin. Resistance shall be 100 megohm, minimum.

3/(4 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 411 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES OVERSPEED INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 ................... 0 Alphabetical Index Page

Subject Gas Generator Overspeed Inspection................................................................................. Power Turbine Overspeed Inspection. ...............................................................................

3 4

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 411 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for LM2500+ Models GK, GV gas generators and Model PK gas turbine overspeed inspections. For LM2500+ Model PV gas turbine overspeed inspection, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions.

2.

Reference Material. Number

Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Procedures WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator/Gas Turbine Shipping WP 502 00 Power Turbine Shipping WP 503 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 411 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Gas Generator Overspeed Inspection. CAUTION DO NOT ATTEMPT TO MOTOR OR OPERATE ENGINE IF OVERSPEED CONDITION HAS OCCURRED, UNTIL THOROUGH INVESTIGATION OF CONDITION HAS BEEN COMPLETED. NOTE Gas generator overspeed condition exists when high pressure compressor (HPC) rotor speed exceeds 10,370 revolutions per minute (RPM). a.

Comply with all instructions contained in WP 002 00.

b.

Following shutdown of engine, due to gas generator overspeed condition, proceed as follows:

c.

(1)

Check gas generator instrumentation for correct operation.

(2)

Consult packager’s manual to check packager supplied control hardware and software for correct operation.

If no problems are found with instrumentation, proceed as follows: (1)

Consult packager’s manual to determine HPC rotor maximum recorded speed during overspeed condition.

(2)

Remove gas generator per WP 301 00 or gas turbine per WP 300 00.

(3)

Ship gas generator to depot for inspection per WP 502 00.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 411 00 7.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Power Turbine Overspeed Inspection. CAUTION DO NOT ATTEMPT TO MOTOR OR OPERATE ENGINE IF OVERSPEED CONDITION HAS OCCURRED, UNTIL THOROUGH INVESTIGATION OF CONDITION HAS BEEN COMPLETED. NOTE Power turbine overspeed condition exists when power turbine rotor speed exceeds 4,978 RPM. a.

Following emergency shutdown of engine, due to power turbine overspeed condition, proceed as follows: (1)

For six stage power turbines, proceed as follows: (a) Check power turbine instrumentation for correct operation. (b) Consult packager’s manual to check packager supplied control hardware and software for correct operation.

(2) b.

For two stage power turbines, consult GEK 105052.

If no problems are found with instrumentation, proceed as follows: (1)

Consult packager’s manual to determine power turbine rotor maximum recorded speed during overspeed condition.

(2)

If power turbine rotor speed of greater than 4,978 RPM is confirmed, proceed as follows: (a) Remove power turbine per WP 302 00. (b) Ship power turbine to depot for inspection per WP 503 00.

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 412 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES OVERTEMPERATURE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 .................... 0 Alphabetical Index Page

Subject Overtemperature Inspection. .............................................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 412 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for inspection of LM2500+ Models GK and GV gas generators and Model PK gas turbine when an overtemperature condition has occurred. Overtemperature condition occurs when engine operating temperature exceeds limits established in GEK 105054, Chapter 7. Inspect LM2500+ Model PV gas turbine per GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Gas Generator/Gas Turbine Shipping WP 502 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 412 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Overtemperature Inspection. NOTE

•

Transients into Area A do not require an overtemperature inspection, but cause of transient should be found and corrected.

•

Transients into Area B require an overtemperature inspection. If more than one transient into Area B occurs, record the first transient in engine records and find and correct cause of transient.

•

Any transient into Area C requires an overtemperature inspection. CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, LOAD-SHEDDING, OR OTHER PROBLEMS THAT INITIATE EMERGENCY SHUTDOWNS OR ABORTED OPERATIONS WITHOUT THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN DAMAGE AND ULTIMATE FAILURE. a.

Comply with all instructions contained in WP 002 00.

b.

Following shutdown of engine due to overtemperature condition (figure 1), proceed as follows: (1)

Check engine instrumentation for correct operation.

(2)

Check all engine and packager supplied cabling.

(3)

Consult packager’s manual to check packager supplied control hardware and software for correct operation.

c.

If two stage power turbine is installed, consult GEK 105052, Operations and Maintenance Manual, for disposition of power turbine.

d.

If no problems are found in engine instrumentation, cabling, or control system, remove gas turbine per WP 300 00, or gas generator per WP 301 00.

e.

Install gas generator or gas turbine into shipping container per WP 502 00.

f.

Ship gas generator or gas turbine to depot for further inspection.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 412 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Transient Temperature Limits 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR MISCELLANEOUS SUMP COMPONENTS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 22 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 22 ................. 0 Alphabetical Index Subject

Page

Engine Bearings Inspection................................................................................................ Insulation Blankets Inspection. ......................................................................................... Lube Oil Nozzles Inspection ............................................................................................... Miscellaneous Sump Components Inspection.................................................................... Rotating Air and Oil Seals Inspection................................................................................ Spanner Nuts Inspection. ................................................................................................... Stationary Air and Oil Seals Inspection. ...........................................................................

15 10 11 13 8 8 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for LM2500+ Models GK and GV gas generator, and Model PV gas turbine, inspection of A-, B-, and C-sump components.

2.

3.

4.

5.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement Compressor Front Frame Replacement Gas Generator Assembly Replacement High Pressure Compressor Rotor Inspection High Pressure Turbine Inspection

GEK 105054 WP 002 00 WP 200 00 WP 201 00 WP 210 00 WP 301 00 WP 424 00 WP 426 00

Support Equipment. Nomenclature

Part No.

Comparator, Optical - Pocket Sized

Local Purchase

Consumable Material. Nomenclature

Part No./Specification

Isopropyl Alcohol Lubricating Oil

Fed Spec TT-I-735 MIL-L-23699 or MIL-L-7808

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

GEK 105054 Volume II WP 413 00

Stationary Air and Oil Seals Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing compressor front frame (CFF) per WP 210 00.

c

Expose B-sump as follows:

d.

e.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove turbine mid frame (TMF) per WP 200 00.

(3)

Remove high pressure turbine (HPT) rotor per WP 201 00.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect stationary air and oil seals per table 1 and figure 1.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

Replacement of A-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

B-sump field level component replacement is limited to the aft stationary air seal. Repair of any other B-sump component requires gas generator replacement.

•

Replacement of C-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to TMF replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 1. Stationary Air And Oil Seals

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

l. All Areas for: a. Cracks Not serviceable Not repairable 2. Seal Surfaces (Metallic Honeycomb Seal Material) for: a. Rubs or See figure l for wear Not repairable grooves groove depth limits 3. Seal Surfaces (Abradable Seal Material) for: a Rubs, grooves, Depth of damage Not repairable or missing not to exceed 50 pieces percent of rub material thickness 4. Mating (Sealing) Surfaces for: a. Pickup and Not serviceable Any amount high metal b. Nicks, dents, Any number, any Not repairable and scratches length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across sealing surface

On-Site Corrective Action See NOTE See NOTE

See NOTE

Remove pickup and high metal Replace part

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Stationary Air And Oil Seals - (Cont.)

Inspect 5. Threads for: a. Damage

On-Site Maximum Serviceable Limits

Not serviceable

On-Site Maximum Repairable Limits

All thread pickup and high metal shall be removed. Total removal of damage shall not exceed accumulated length of one full thread 6. HPT Cooling and Vent Stationary Air Seal for: a. Flange 0.020 in. (0.50 mm) Any amount distortion at as measured with jackscrew 6.0 in. (152 mm) parallel bar and depth micrometer b. Flange mating Not serviceable Not repairable surface c. Stripped jackNot serviceable Not repairable screw holes d. Damaged Not serviceable Not repairable bolthole

On-Site Corrective Action

Chase threads

Straighten. Inspect for cracks. If cracked, replace seal Replace seal Replace seal Replace seal

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure l. Engine Bearing Stationary Air and Oil Seals (Sheet 1 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 413 00

Figure 1. Engine Bearing Stationary Air and Oil Seals (Sheet 2 of 2) 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00 7.

8.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Rotating Air and Oil Seals Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Inspect A-sump rotating component per WP 424 00.

c.

Inspect B- and C-sump rotating components per WP 426 00.

Spanner Nuts Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose C-sump as follows:

d.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect No. 3R and No. 5R bearing spanner nuts per table 2 and figure 2. Table 2. No. 3 and No. 5 Bearing Spanner Nuts

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace nut

WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. b.

Missing silver plating on all areas, except threads (No. 5 bearing only)

Any amount, if no corrosion is evident

Remove corrosion. Apply lubricating oil as protective coating

c.

Nicks, dents, or scratches

Any number, 0.031 in. (0.78 mm) deep, after removal of high metal

Not repairable

Replace nut

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 3 and No. 5 Bearing Spanner Nuts - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of damage in other threads shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to remove protective finish unnecessarily. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Silver plating or black oxide finish missing

50 percent missing

Not repairable

Replace spanner nut

Not serviceable

Any amount

Remove high metal

Not serviceable

25 percent of slot height can be removed by blending to radius

Blend

3. Mating (Seating) Surfaces for: a.

Pickup and high metal

4. Tab Slots for: a.

Turned metal or cracked corners

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. No. 3R and No. 5R Bearing Spanner Nuts 9.

Insulation Blankets Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose C-sump as follows:

c.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect C-sump insulation blankets per table 3.

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Insulation Blankets

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Discoloration

Any amount

b.

Soot or oil accumulation (externally)

Any amount

Removal of soot or oil accumulation is desirable before being reinstalled

c.

Oil soaking (internally)

Not serviceable

Not repairable

Replace blanket

d.

Charring or burning

Not serviceable

Not repairable

Replace blanket

e.

Missing or loose capstan

Not serviceable

Not repairable

Replace blanket

f.

Holes

Six per side, 0.125 in. (3.17 mm) diameter, at least 6.0 in. (152 mm) apart

Six per side, 0.250 in. (6.35 mm) diameter, at least 6.0 in. (152 mm) apart

Replace blanket

g.

Rips or cracks

12 per side, 0.125 in. (3. 17 mm) long, at least 6.0 in. (152 mm) apart

Any number, 1.0 in. (25 mm) long, at least 6.0 in. (152 mm) apart

Replace blanket

h.

Wrinkles, dents, or snags

Any number, that does not penetrate foil skin

Any amount can be re-formed

Re-form blanket

10. Lube Oil Nozzles Inspection a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose C-sump as follows:

d.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect lube oil nozzle per table 4.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Lube Oil Nozzle On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Nicks, dents, and scratches (except orifices)

Any number, 0.031 in. (0.78 mm) deep, if it does not affect oil flow direction, quantity, or pattern, and does not exceed 20 percent of lube jet housing dimension adjacent to damaged area

Not repairable

Replace nozzle*

c.

Sharp (creased) bends

Not serviceable

Not repairable

Replace nozzle*

Not serviceable

Not repairable

Replace nozzle*

2. Orifices for: a.

Damage that restricts and/or distorts flow in orifice

WARNING

•

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.

• ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Contamination

Not serviceable

Any amount that can be completely removed

Clean, with isopropyl alcohol and clean shop air

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Lube Oil Nozzle

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Gasket Sealing Surface for: a.

Nicks and scratches

Any number, 0.010 in. (0.25 mm) in depth, after removal of high metal, if defect does not extend completely across sealing surface where gasket is placed

Not repairable

Replace nozzle*

* May be repairable. Consult GE for disposition of replaced parts. 11. Miscellaneous Sump Components Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c

Expose B-sump as follows:

d.

e.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

(3)

Remove HPT rotor per WP 201 00.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect miscellaneous sump components per table 5.

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Miscellaneous Sump Components

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

RETAINING RINGS, LOCKPLATE (NO. 5 BEARING) AND SPACERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Missing black oxide finish

Any amount, if no corrosion is evident

c.

Nicks or scratches

Any number, 0.005 in. (0.12 mm) deep, after removal of high metal

Not repairable

Replace part

d.

Bent or broken tab

Not serviceable

Not repairable

Replace part

e.

Ring bent out of alignment

Not serviceable

Not repairable

Replace part

Not serviceable

Not repairable

Replace part. If damage was caused from gas turbine operation, replace No. 5 bearing also

Not repairable

Replace part

Remove all corrosion and apply protective coating

2. Lockplate Lugs for: a.

Distortion

HEAT AND OIL SHIELDS 1. All Areas for: a.

Cracks in body

Not serviceable

b.

Nicks and scratches

Any number, any length, if they do not penetrate completely through parent metal. Remove high metal. Surfaces in mating areas shall be smooth

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Miscellaneous Sump Components

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: - (cont.) c.

Dents

Any number, 0.031 in. (0.78 mm) deep that shall not interfere with installation

Any number, any depth, that can be re-formed to near original contour and shall assemble properly

Re-form, as nearly as possible, to original contour with hand tools. Inspect for cracks. Replace if cracked

d.

Distortion

Not serviceable

Any amount that can be re-formed to near original contour and shall assemble properly

Use hand tools to re-form as nearly as possible to original contour. Inspect for cracks. Replace if cracked

12. Engine Bearings Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose B-sump as follows:

d.

e.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

(3)

Remove HPT rotor per WP 201 00.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Inspect all bearings per table 6. If defect is accessible, and can be felt with recommended scriber, determine defect dimensions with pocket-sized optical comparator.

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

•

NO. 3R AND NO. 5R BEARINGS ARE MATCHED ASSEMBLIES. MIXING COMPONENTS FROM MATCHED BEARING ASSEMBLIES CAN RESULT IN ENGINE FAILURE. NOTE

•

Matched bearing assembly comprises inner race, cage, balls/rollers, and outer race.

•

Replacement of No. 3R bearing shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation and No. 3R. bearing inner race replacement. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

No. 4B and 4R bearings are not field replaceable. If bearings are found beyond on-site serviceable limits, replace gas generator.

•

Replacement of No. 5R bearing shall be accomplished at depot level. Field level maintenance is limited to TMF and No. 5R bearing inner race replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 6. Engine Bearings

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: a.

Fatigue pitting, spalling (as evidenced by relatively deep cavities with fractured appearance on sides), and cracks

Not serviceable

Not repairable

See CAUTION and NOTE

16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: - (cont.) b.

Corrosion pitting (as evidenced by relatively shallow irregularly shaped ragged cavities with either reddish or dark color)

Any number, that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

c.

Rollers for axial scratches or scores

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

d.

Balls or rollers for crossed scratches

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber when passed lightly across junction(s) of scratches

Not repairable

See CAUTION and NOTE

e.

Circumferential scratches or scores

Acceptable, if not detected with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

f.

Nicks and dents

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: - (cont.) g.

Skidding wear, as can be visually apparent by burnished over-all appearance or flat spots

Not serviceable

Not repairable

See CAUTION and NOTE

h.

Heat discoloration

Accept bright polished steel to straw color only

Not repairable

See CAUTION and NOTE

i.

True brinnelling

Not serviceable

Not repairable

See CAUTION and NOTE

j.

Stains

Any amount

k.

Fit in cage pocket

No tightness allowed. Elements shall be retained

Not repairable

See CAUTION and NOTE

l.

End wear on rollers of No. 3 bearing

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Inner and/or Outer Races for: a.

Fatigue pitting, spalling (as evidenced by relatively deep cavities with fractured appearance on sides), and cracks

Not serviceable

Not repairable

See CAUTION and NOTE

b.

Corrosion and pitting (as evidenced by relatively shallow irregular shaped ragged cavities with either reddish or dark color)

Not serviceable

Not repairable

See CAUTION and NOTE

(1)

Active surfaces on separable races

Any number, that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

(2)

Nonactive surfaces

Acceptable, if pits cannot be detected by 0.045 in. (1.14 mm) radius scriber after localized hand polishing with crocus cloth. After polishing, surface finish shall be as smooth as original

Not repairable

See CAUTION and NOTE

19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Inner and/or Outer for Races: - (cont.) NOTE No polishing is permitted on active surfaces. c.

d.

Scratches and scores (1)

Active surfaces

Acceptable, if cannot be felt with 0.030 in. (0.76 mm) radius scriber, after removal of high metal

Not repairable

See CAUTION and NOTE

(2)

Nonactive surfaces

Acceptable, if cannot be felt with 0.045 in. (1.14 mm) radius scriber, after removal of high metal

Not repairable

See CAUTION and NOTE

Nicks, dents, or indentations

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

(1)

For bearings with rolling elements less than 0.500 in. (12.70 mm) diameter, 0.030 in. (0.76 mm) in greatest dimension. With rolling elements greater than 0.500 in. (12.70 mm) diameter, 0.040 in. (1.01 mm) in greatest dimension

Not repairable

See CAUTION and NOTE

Active surfaces

20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Inner and/or Outer for Races: - (cont.) (2) Nonactive surfaces

0.090 in. (2.28 mm) in greatest dimension, 0.030 in. (0.76 mm) in axial direction, if damage extends into active surface of race. Remove high metal on clamping surfaces

Not repairable

See CAUTION and NOTE

Not repairable

See CAUTION and NOTE

e.

True brinelling

Not serviceable

f.

Stains

Any amount

g.

Skidding wear, as can be visually apparent by burnished overall appearance, or localized smearing or wiping of material

Not serviceable

Not repairable

See CAUTION and NOTE

3. Cages for: a.

Chips, cracks, distortion, or heat discoloration of plated surfaces

Not serviceable

Not repairable

See CAUTION and NOTE

b.

Missing or worn rolling element retainers

Not serviceable

Not repairable

See CAUTION and NOTE

c.

Smooth indentations

Accept defects 0.200 in. (5.08 mm) in greatest dimension, if they do not extend into or deform functional surfaces

Not repairable

See CAUTION and NOTE

21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Cages for: - (cont.) d.

Wear through of plating in ball or roller pockets down to cage parent metal

Not serviceable

Not repairable

See CAUTION and NOTE

e.

Stains

Any amount

f.

Heat discoloration

Straw color acceptable

Not repairable

See CAUTION and NOTE

g.

Silver plating

Missing plating on nonfunctional cage surfaces is acceptable

Not repairable

See CAUTION and NOTE

22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

SUBORDINATE WORK PACKAGE

TECHNICAL PROCEDURES GAS TURBINE MISCELLANEOUS SUMP COMPONENTS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE SWP PAGES Total Number of Pages in this SWP is 28 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 27 ................. 0 28 Blank............ 0 Alphabetical Index Subject

Page

Engine Bearings Inspection................................................................................................ Insulation Blankets Inspection. ......................................................................................... Lube Oil Nozzles Inspection. .............................................................................................. Miscellaneous Sump Components Inspection.................................................................... Rotating Air and Oil Seals Inspection................................................................................ Spanner Nuts Inspection. ................................................................................................... Stationary Air and Oil Seals Inspection. ...........................................................................

20 14 16 17 9 11 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for inspection of A-, B-, C-, and D-sump components.

2.

3.

4.

5.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement Compressor Front Frame Replacement Gas Generator and Power Turbine Separation and Joining Gas Generator Assembly Replacement High Pressure Compressor Rotor Inspection High Pressure Turbine Inspection

GEK 105054 WP 002 00 WP 200 00 WP 201 00 WP 210 00 WP 216 00 WP 301 00 WP 424 00 WP 426 00

Support Equipment. Nomenclature

Part No.

Comparator, Optical - Pocket Sized

Local Purchase

Consumable Material Nomenclature

Part No./Specification

Isopropyl Alcohol Lubricating Oil

Fed Spec TT-I-735 MIL-L-23699 or MIL-T-5544

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

GEK 105054 Volume II SWP 413 01

Stationary Air and Oil Seals Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing compressor front frame (CFF) per WP 210 00.

c.

Expose B-sump as follows:

d.

(1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove turbine mid frame (TMF) per WP 200 00.

(3)

Remove high pressure turbine (HPT) rotor per WP 201 00.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

e.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

f.

Inspect stationary air and oil seals per table 1 and figure 1.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

Replacement of A-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

B-sump field level component replacement is limited to the aft stationary air seal. Repair of any other B-sump component requires gas generator replacement.

•

Replacement of C-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to TMF replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 1. Stationary Air And Oil Seals

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. All Areas for: a.

Cracks

Not serviceable

Not repairable

See NOTE

2. Seal Surfaces (Metallic Honeycomb Seal Material) for: a.

Rubs or grooves

See figure l for wear groove depth limits

Not repairable

See NOTE

Not repairable

See NOTE

3. Seal Surfaces (Abradable Seal Material) for: a.

Rubs, grooves, or missing pieces

Depth of damage not to exceed 50 percent of rub material thickness

4. Mating (Sealing) Surfaces for: a.

Pickup and high metal

Not serviceable

Any amount

Remove pickup and high metal

b.

Nicks, dents, and scratches

Any number, any length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across sealing surface

Not repairable

See NOTE

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Stationary Air And Oil Seals - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of damage shall not exceed accumulated length of one full thread

Chase threads

6. HPT Cooling and Vent Stationary Air Seal for: a.

Flange distortion at jackscrew

0.020 in. (0.50 mm) as measured with 6.0 in. (152 mm) parallel bar and depth micrometer

Any amount

Straighten. Inspect for cracks. If cracked, replace seal

b.

Flange mating surface

Not serviceable

Not repairable

See NOTE

c.

Stripped jackscrew holes

Not serviceable

Not repairable

See NOTE

d.

Damaged bolthole

Not serviceable

Not repairable

See NOTE

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure l. Engine Bearing Stationary Air and Oil Seals (Sheet 1 of 3) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II SWP 413 01

Figure 1. Engine Bearing Stationary Air and Oil Seals (Sheet 2 of 3) 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Engine Bearing Stationary Air and Oil Seals (Sheet 3 of 3) 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 7.

Rotating Air and Oil Seals Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Inspect A-sump rotating component per WP 424 00.

c.

Inspect B-sump rotating components per WP 426 00.

d.

Expose C-sump components as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

e.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

f.

Inspect engine bearing rotating air and oil seals per table 2 and figure 2. Table 2. No. 6R Bearing Rotating Air And Oil Seals

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Cracks-except seal serration outside diameter (OD)

Not serviceable

Not repairable

Replace part

2. Mating (Seating) Surfaces for: a.

Pickup and high metal

Not serviceable

Any amount

Remove pickup and high metal

b.

Nicks, dents, scores, and scratches on end faces

Any number, any length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across seating surface

Not repairable

Replace part

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 6R Bearing Rotating Air And Oil Seals - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Mating (Seating) Surfaces for: - (cont.) c.

Nicks or dents on OD

Three per 6.0 in. (152 mm) of each serration circumference, 0.047 in. (1.19 mm) deep and 0.125 in. (3.17 mm) long, after removal of high metal

Not repairable

Replace part

3. Seal Serrations for: a.

Wear at OD

Within serviceable limits of figure 2

Not repairable

Replace part

b.

Turned metal on serration OD

Any amount, if OD wear limit is not exceeded, after removal of high metal

Not repairable

Replace part

c.

Nicks or dents on face

Any number, 0.031 in. (0.78 mm) deep, after removal of high metal

Not repairable

Replace part

d.

Cracks originating from OD

Not serviceable

Three cracks per 6.0 in. (152 mm) of each serration circumference can be blended out to depth of 0.047 in. (1.19 mm) and 0.125 in. (3.17 mm) long

Blend. Inspect after blending

e.

Aluminum oxide coating missing (where applicable)

40 percent can be missing on outer portion that mates to stationary seal

Not repairable

Replace part

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 6R Bearing Rotating Air And Oil Seals - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Seal Bore for: a.

8.

Axial score marks

Any number, any length, 0.010 in. (0.25 mm) deep and 0.031 in. (0.78 mm) wide, after removal of high metal, if no more than five percent of area is affected in any 90 degree sector

Not repairable

Replace part

Spanner Nuts Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

d.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

e.

Inspect No. 3R, No. 5R, and No. 6R bearing spanner nuts per table 3 and figure 3.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. No. 6R Bearing Rotating Air and Oil Seals 12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. No. 3, No. 5, and No. 6 Bearing Spanner Nuts

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace nut

WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. b.

Missing silver plating on all areas, except threads (No. 5 bearing only)

Any amount, if no corrosion is evident

Remove corrosion. Apply lubricating oil as protective coating

c.

Nicks, dents, or scratches

Any number, 0.031 in. (0.78 mm) deep, after removal of high metal

Not repairable

Replace nut

2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of damage in other threads shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to remove protective finish unnecessarily. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Silver plating or black oxide finish missing

50 percent missing

Not repairable

Replace spanner nut

Any amount

Remove high metal

3. Mating (Seating) Surfaces for: a.

Pickup and high metal

Not serviceable

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. No. 3, No. 5, and No. 6 Bearing Spanner Nuts - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Tab Slots for: a.

9.

Turned metal or cracked corners

Not serviceable

25 percent of slot height can be removed by blending to radius

Blend

Insulation Blankets Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

Figure 3. No. 3R, No. 5R, and No. 6R Bearing Spanner Nuts 14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines c.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

d.

Inspect C-sump insulation blankets per table 4. Table 4. Insulation Blankets

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Discoloration

Any amount

b.

Soot or oil accumulation (externally)

Any amount

Removal of soot or oil accumulation is desirable before being reinstalled

c.

Oil soaking (internally)

Not serviceable

Not repairable

Replace blanket

d.

Charring or burning

Not serviceable

Not repairable

Replace blanket

e.

Missing or loose capstan

Not serviceable

Not repairable

Replace blanket

f.

Holes

Six per side, 0.125 in. (3.17 mm) diameter, at least 6.0 in. (152 mm) apart

Six per side, 0.250 in. (6.35 mm) diameter, at least 6.0 in. (152 mm) apart

Replace blanket

g.

Rips or cracks

12 per side, 0.125 in. (3. 17 mm) long, at least 6.0 in. (152 mm) apart

Any number, 1.00 in. (25.4 mm) long, at least 6.0 in. (152 mm) apart

Replace blanket

h.

Wrinkles, dents, or snags

Any number, that does not penetrate foil skin

Any amount can be re-formed

Re-form blanket

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

10. Lube Oil Nozzles Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

d.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

e.

Inspect lube oil nozzle per table 5. Table 5. Lube Oil Nozzle

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Nicks, dents, and scratches (except orifices)

Any number, 0.031 in. (0.78 mm) deep, if it does not affect oil flow direction, quantity, or pattern, and does not exceed 20 percent of lube jet housing dimension adjacent to damaged area

Not repairable

Replace nozzle*

c.

Sharp (creased) bends

Not serviceable

Not repairable

Replace nozzle*

Not serviceable

Not repairable

Replace nozzle*

2. Orifices for: a.

Damage that restricts and/or distorts flow in orifice

16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Lube Oil Nozzle On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Orifices for: - (cont.) WARNING

b.

•

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.

•

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

Contamination

Not serviceable

Any amount that can be completely removed

Clean, with isopropyl alcohol and clean shop air

Not repairable

Replace nozzle*

3. Gasket Sealing Surface for: a.

Nicks and scratches

Any number, 0.010 in. (0.25 mm) in depth, after removal of high metal, if defect does not extend completely across sealing surface where gasket is placed

* May be repairable. Consult GE for disposition of replaced parts. 11. Miscellaneous Sump Components Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose B-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

(3)

Remove HPT rotor per WP 201 00. 17

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01 d.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

e.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

f.

Inspect miscellaneous sump components per table 6. Table 6. Miscellaneous Sump Components

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

RETAINING RINGS, LOCKPLATE (NO. 5R BEARING), AND SPACERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Missing black oxide finish

Any amount, if no corrosion is evident

c.

Nicks or scratches

Any number, 0.005 in. (0.12 mm) deep, after removal of high metal

Not repairable

Replace part

d.

Bent or broken tab

Not serviceable

Not repairable

Replace part

e.

Ring bent out of alignment

Not serviceable

Not repairable

Replace part

Not serviceable

Not repairable

Replace part. If damage was caused from gas turbine operation, replace No. 5 bearing also

Remove all corrosion and apply protective coating

2. Lockplate Lugs for: a.

Distortion

18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Miscellaneous Sump Components - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

HEAT AND OIL SHIELDS 1. All Areas for: a.

Cracks in body

Not serviceable

Not repairable

Replace part

b.

Nicks and scratches

Any number, any length, if they do not penetrate completely through parent metal. Remove high metal. Surfaces in mating areas shall be smooth

c.

Dents

Any number, 0.031 in. (0.78 mm) deep that shall not interfere with installation

Any number, any depth, that can be re-formed to near original contour and shall assemble properly

Re-form, as nearly as possible, to original contour with hand tools. Inspect for cracks. Replace if cracked

d.

Distortion

Not serviceable

Any amount that can be re-formed to near original contour and shall assemble properly

Use hand tools to re-form as nearly as possible to original contour. Inspect for cracks. Replace if cracked

19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

12. Engine Bearings Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose B-sump as follows:

d.

(1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

(3)

Remove HPT rotor per WP 201 00.

Expose C-sump as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)

Remove TMF per WP 200 00.

e.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

f.

Inspect all bearings per table 7. If defect is accessible, and can be felt with recommended scriber, determine defect dimensions with pocket-sized optical comparator.

20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

•

NO. 3R AND NO. 5R BEARINGS ARE MATCHED ASSEMBLIES. MIXING COMPONENTS FROM MATCHED BEARING ASSEMBLIES CAN RESULT IN ENGINE FAILURE. NOTE

•

Matched bearing assembly comprises inner race, cage, balls/rollers, and outer race.

•

Replacement of No. 3R bearing shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation and No. 3R. bearing inner race replacement. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

Replacement of No. 5R bearing shall be accomplished at depot level. Field level maintenance is limited to TMF and No. 5R bearing inner race replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race.

•

No. 4B, 4R, 7B, and 7R bearings are not field replaceable. If No. 4B and 4R bearings are found beyond on-site serviceable limits, replace gas generator. If No. 7B and 7R bearings are found beyond on-site serviceable limits, replace power turbine. Table 7. Engine Bearings

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: a.

Fatigue pitting, spalling (as evidenced by relatively deep cavities with fractured appearance on sides), and cracks

Not serviceable

Not repairable

See CAUTION and NOTE

21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: - (cont.) b.

Corrosion pitting (as evidenced by relatively shallow irregularly shaped ragged cavities with either reddish or dark color)

Any number that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

c.

Rollers for axial scratches or scores

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

d.

Balls or rollers for crossed scratches

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber when passed lightly across junction(s) of scratches

Not repairable

See CAUTION and NOTE

e.

Circumferential scratches or scores

Acceptable, if not detected with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

f.

Nicks and dents

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

(1)

0.020 in. (0.50 mm) in greatest dimension

Not repairable

See CAUTION and NOTE

Elements less than 0.500 in. (12.70 mm) diameter

22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

l. Ball and Rollers for: - (cont.) (2)

Elements 0.500 in. (12.70 mm) diameter but less than 0.750 in. (19.05 mm) diameter

0.035 in. (0.88 mm) in greatest dimension

Not repairable

See CAUTION and NOTE

(3)

Elements 0.750 in. (19.05 mm) and greater

0.050 in. (1.27 mm) in greatest dimension

Not repairable

See CAUTION and NOTE

g.

Skidding wear, as can be visually apparent by burnished over-all appearance or flat spots

Not serviceable

Not repairable

See CAUTION and NOTE

h.

Heat discoloration

Accept bright polished steel to straw color only

Not repairable

See CAUTION and NOTE

i.

True brinnell

Not serviceable

Not repairable

See CAUTION and NOTE

j.

Stains

Any amount

k.

Fit in cage pocket

No tightness allowed. Elements shall be retained

Not repairable

See CAUTION and NOTE

l.

End wear on rollers of No. 3 bearing

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Inner and/or Outer Races for: a.

Fatigue pitting, spalling (as evidenced by relatively deep cavities with fractured appearance on sides), and cracks

Not serviceable

Not repairable

See CAUTION and NOTE

b.

Corrosion and pitting (as evidenced by relatively shallow irregular shaped ragged cavities with either reddish or dark color)

Not serviceable

Not repairable

See CAUTION and NOTE

(1)

Active surfaces on separable races

Any number, that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

(2)

Nonactive surfaces

Acceptable, if pits cannot be detected by 0.045 in. (1.14 mm) radius scriber after localized hand polishing with crocus cloth. After polishing, surface finish shall be as smooth as original

Not repairable

See CAUTION and NOTE

24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

NOTE No polishing is permitted on active surfaces. 2. Inner and/or Outer Races for: - (cont.) c.

d.

Scratches and scores (1)

Active surfaces

Acceptable, if cannot be felt with 0.030 in. (0.76 mm) radius scriber after removal of high metal

Not repairable

See CAUTION and NOTE

(2)

Nonactive surfaces

Acceptable, if cannot be felt with 0.045 in. (1.14 mm) radius scriber after removal of high metal

Not repairable

See CAUTION and NOTE

Nicks, dents, or indentations

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable

See CAUTION and NOTE

(1)

For bearings with rolling elements less than 0.500 in. (12.70 mm) diameter, 0.030 in. (0.76 mm) in greatest dimension. With rolling elements greater than 0.500 in. (12.70 mm) diameter, 0.040 in. (1.01 mm) in greatest dimension

Not repairable

See CAUTION and NOTE

Active surfaces

25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Inner and/or Outer Races for: - (cont.) (2)

Nonactive surfaces

0.090 in. (2.28 mm) in greatest dimension, 0.030 in. (0.76 mm) in axial direction, if damage extends into active surface of race. Remove high metal on clamping surfaces

Not repairable

See CAUTION and NOTE

Not repairable

See CAUTION and NOTE

e.

True brinelling

Not serviceable

f.

Stains

Any amount

g.

Skidding wear, as can be visually apparent by burnished overall appearance, or localized smearing or wiping of material

Not serviceable

Not repairable

See CAUTION and NOTE

3. Cages for: a.

Chips, cracks, distortion, or heat discoloration of plated surfaces

Not serviceable

Not repairable

See CAUTION and NOTE

b.

Missing or worn rolling element retainers

Not serviceable

Not repairable

See CAUTION and NOTE

c.

Smooth indentations

Accept defects 0.200 in. (5.08 mm) in greatest dimension, if they do not extend into or deform functional surfaces

Not repairable

See CAUTION and NOTE

26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 413 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.) Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Cages for: - (cont.) d.

Wear through of plating in ball or roller pockets down to cage parent metal

Not serviceable

Not repairable

See CAUTION and NOTE

e.

Stains

Any amount

f.

Heat discoloration

Straw color acceptable

Not repairable

See CAUTION and NOTE

g.

Silver plating

Missing plating on nonfunctional cage surfaces is acceptable

Not repairable

See CAUTION and NOTE

27/(28 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 414 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE OFF-SCHEDULE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 ................... 0 Alphabetical Index Page

Subject Variable Stator Vane Off-Schedule Operation Inspection. ...............................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 414 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introdu ction. Variable stators vanes (VSV) operated with misassembled, bent, or broken actuation arms, with broken connector links, or with actuation rings with elongated actuation arm pinholes will result in off-schedule vane condition that requires special handling of high pressure compressor (HPC) rotor blades in stage adjacent to vane stage containing discrepant actuation arm or connector link.

2.

3.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Rotor Blades Replacement External Engine Inspection Borescope Inspection

GEK 105054 WP 002 00 WP 215 00 WP 403 00 WP 406 00

Support Equipment. Nomenclature

Part No.

Protractor, Electronic Gage, Sight - VSV Actuation Arms Gage, Sight - VSV Stage 5 Actuation Arms

1C8070G06 2C6966G07 2C8016G03

4.

Consumable Material. None required.

5.

Expendable Material. None required

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 414 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Variable Stator Vane Off-Schedule Operation Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Inspect external engine surfaces per WP 403 00.

c.

Inspect VSV actuation arms as follows: (1)

Inspect inlet guide vane (IGV) and stages 0 through 6 vanes for off-schedule condition. Inspect vanes (figure 1) for conditions listed in table 1.

(2)

Visually inspect IGV and stage 0 actuation arms for broken, distorted, or bent arms. Replace any arms found in this condition.

(3)

Using sight gage tools, determine amount of off-schedule as follows: (a) Using sight gage, 2C6966, determine angle for stages 1 through 4. (b) Using sight gage, 2C8016, determine angle for stages 5 and 6. (c) If desired, electronic protractor, 1C8070, can be used in place of sight gages when checking for off-schedule angles.

(4)

Locate gage over vane tangs and around retaining nut and sleeve. Clear Plexiglas arm extends over lever arm and has lines scribed at 0 degrees ± 2 degrees, and ± 4 degrees. Table 1. VSV Off-Schedule Conditions

Condition

Indication

Inspection

NOTE Use sight gage tools to determine amount of off-schedule. 1.

Bent, distorted, or broken actuation arms or connector links

VSV actuation components are often damaged during maintenance procedures. Figure 1 shows typical actuation arm damage

Inspect VSV actuation hardware for general conditions per paragraph 6

2.

Misassembled actuation arms to connector links (at 3:00 and 9:00 o’clock positions)

Actuation arm pins can be installed in connector link recess areas instead of correct pinholes

Check connector link actuation arms for side to side (loose) movement

3.

Actuation rings or actuation arms with elongated pinholes

Excessive wear of actuation arm pin, actuation ring, or pin is not secure (loose) to actuation arm

Check actuation arms for side to side (loose) movement

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 414 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Variable Stator Vane Actuation Arm Inspection d.

If off-schedule condition is found, proceed as follows: (1)

Record affected stage and number of degrees of off-schedule condition.

(2)

Complete corrective action requirements per table 2. Table 2. VSV Off-Schedule Corrective Action Condition

Corrective Action

1.

Off-Schedule is 2 degrees or less

No action required

2.

Off-schedule is more than 2 degrees but less than 4 degrees

a. Replace defective VSV actuation components b. Perform borescope inspection of one stage forward and two stages aft of affected stage per WP 406 00

3.

Off-schedule is 4 degrees or more, or has broken connector link on: IGV

Perform borescope inspection of two stages aft of affected stage per WP 406 00

Stage 0

Replace two downstream stages of HPC rotor blades per WP 215 00

Stages 1 through 6 vanes

Replace one upstream and two downstream stages of HPC rotor blades per WP 215 00

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES FUEL SYSTEM INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 8 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 7 ................... 0 8 Blank ............. 0 Alphabetical Index Page

Subject Fuel System Inspection.......................................................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for visual inspection of the fuel system.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Replacement

GEK 105054 WP 002 00 WP 101 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Fuel System Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Inspect fuel system per table 1 and figures 1 through 4. Table 1. Fuel System Inspection Inspect

On-Site Maximum Serviceable Limits

FUEL MANIFOLDS 1. Liquid Fuel Manifold for: a. Cracks and Not serviceable splits b. Dents and flat Any number on areas shrouded portion c. Nicks and Any number, 0.005 scores in. (0.13 mm) deep d. Wear at Any number, 0.005 clamping in. (0.13 mm) deep locations e. Misalignment Not serviceable 2. Natural Gas Manifold for: a. Cracks and Not serviceable splits b. Dents and flat Any number, 0.060 areas in. (1.52 mm) deep c. Nicks and Any number, 0.010 scores in. (0.25 mm) deep d. Wear at Any amount, 0.010 clamping in. (0.25 mm) deep locations 3. Dual Fuel/Liquid Manifolds for: a. Cracks and Not serviceable splits b. Dents and flat Any number, 0.020 areas in. (0.51 mm) deep c. Nicks and Any number, 0.005 scores in. (0.13 mm) deep Any amount, 0.020 d. Wear on wear sleeves in. (0.51 mm) deep

On-Site Maximum Repairable Limits

Not repairable Not repairable Not repairable Not repairable

On-Site Corrective Action

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Replace manifold per WP 101 00 Replace manifold per WP 101 00

Any amount

Realign manifold per WP 101 00

Not repairable

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/replace

Not repairable Any number, 0.015 in. (0.38 mm) deep Any amount, 0.015 in. (0.38 mm) deep

Not repairable Not repairable Any number, 0.010 in. (0.25 mm) deep Not repairable

Blend

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/Replace Replace manifold per WP 101 00

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Fuel System Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

3. Dual Fuel/Liquid Manifolds for: (cont.) e. Misalignment Not serviceable 4. Steam Manifold for: a. Cracks and splits b. Dents and flat areas c. Nicks and scores d. Wear at clamping locations e. Misalignment FUEL TUBES 1. Supply Tube for: a. Cracks and splits b. Wrinkles and kinks in bend ID c. Dents and flat areas d. Nicks and scores

On-Site Maximum Repairable Limits

On-Site Corrective Action

Any amount

Realign manifold per WP 101 00

Not serviceable

Not repairable

Any number, 0.060 in. (1.52 mm) Any number, 0.010 in. (0.25 mm) deep Any amount 0.010 in. (0.25 mm) deep

Not repairable

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/Replace

Not serviceable

Any amount

Realign manifold per WP 101 00

Not serviceable

Not repairable

Two percent of tube OD

Not repairable

Replace tube per WP 101 00 Replace tube per WP 101 00

Any number, 0.020 in. (0.51 mm) Any number, 0.005 in. (0.127 mm) deep

Not repairable

Any number, 0.015 in. (0.38 mm) deep Any amount, 0.015 in. (0.38 mm) deep

Any number, 0.010 in. (0.254 mm) deep

e.

Wear at clamping locations

Any amount, 0.005 in. (0.127 mm) deep

Any amount, 0.010 in. (0.254 mm) deep

f.

Misalignment

Not serviceable

Any amount

Blend/Replace

Replace tube per WP 101 00 Blend to remove damage, but not beyond depth of damage. Contour shall be smooth and polished Blend to remove damage, but not beyond depth of damage. Contour shall be smooth and polished Realign tube per WP 101 00

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Fuel System Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Fittings and Connectors for: a.

Leakage

Not serviceable

Light polishing of entire sealing (mating) surfaces to remove scratches is allowed

Polish sealing surface and retorque or replace tube per WP 101 00

b.

Looseness

Not serviceable

Any amount

Retorque tube per WP 101 00

Not serviceable

Not repairable

Replace fuel nozzle per WP 101 00

Not serviceable

Any amount

Remove carbon deposit and inspect for carbon cause

Not serviceable

Not repairable

Replace part

Max of 0.020 in. (0.51 mm) deep

Not repairable

Replace part

FUEL NOZZLES 1. All Fuel Nozzles for a.

Cracks

2. Fuel Nozzle Orifices a.

Carbon deposit or visible plugging

3. Face for: a.

Spalling

4. Tip for: a.

Wear

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 415 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Liquid Fuel Nozzle

Figure 2. Dual Fuel Nozzle 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 415 00

Figure 3. Gas Fuel Nozzle

Figure 4. Gas/Steam Fuel Nozzle 7/(8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES COMPRESSOR FRONT FRAME INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 8 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0 Alphabetical Index Page

Subject Compressor Front Frame Inspection. ................................................................................ Compressor Front Frame Parts Repair. ............................................................................ Compressor Front Frame Parts Replacement. ..................................................................

3 3 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection and repair of the compressor front frame (CFF).

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II Compressor Front Frame Replacement Gas Generator Miscellaneous Sump Components Replacement and Inspection Gas Turbine Miscellaneous Sump Components Replacement and Inspection Illustrated Parts Breakdown

GEK 105054 WP 210 00

3.

Support Equipment. None required.

4.

Consumable Material.

5.

WP 413 00 SWP 413 01 GEK 105055

Nomenclature

Part No./Specification

Dry Ice

Fed Spec BB-C-104

Expendable Material. Not required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Compressor Front Frame Inspection. a.

7.

Inspect CFF per table 1 and figure 1. Refer to WP 413 00 and SWP 413 01 for sump component inspection.

Compressor Front Frame Parts Repair. a.

8.

GEK 105054 Volume II WP 416 00

Repair of CFF parts are limited to CFF replacement, high metal removal, chasing threads or installing inserts, tightening or replacing bolts, tightening or replacing rivets, and replacing nut or gang channel assemblies. See table 1 as applicable.

Compressor Front Frame Parts Replacement. a.

Replace CFF parts as directed during inspection operations. See table 1 as applicable.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. CFF Inspection 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

CASE 1. All Surfaces (unless otherwise specified) for: a. Cracks Not serviceable Not repairable b.

Nicks, scores, and scratches

Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal, if not extended across mating (sealing) surfaces 2. Instrumentation Pads for: a. Damaged Not serviceable threads

3. Forward and Aft Flanges for: a. Cracks One crack per one bolthole per flange from bolthole to outside diameter (OD) b. Deformation Not serviceable

Not repairable

On-Site Corrective Action

Replace CFF per WP 210 00* Replace CFF per WP 210 00*

Any amount

One complete thread can be removed by chasing threads or installing insert

Not repairable

Replace CFF per WP 210 00*

Not repairable

Replace CFF per WP 210 00*

4. Air Seal Pressurization Port and Vent Port Pads for: a. Nicks, scores, Any number, any Not repairable and scratches length, 0.010 in. (0.25 mm) deep, after removal of high metal, if not extended completely across sealing surface b. Damaged Not serviceable Any amount threads

Replace CFF per WP 210 00*

One complete thread can be removed by chasing threads or installing insert 5

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Gas Generator Main Engine Mounts for: a.

Cracks

Not serviceable

Not repairable

Replace CFF per WP 210 00*

b.

Nicks, scores, and scratches

Any number, any length, 0.016 in. (0.41 mm) deep, after removal of high metal

Any amount

Remove high metal and surface blend to original contour

Not serviceable

Not repairable

Replace CFF per WP 210 00*

6. CFF Handling Mounts for: a.

Cracks

STRUTS 1. All Surfaces for: a.

Parent metal cracks

Not serviceable

Not repairable

Replace CFF per Wp 210 00*

b.

Weld cracks

Not serviceable

Not repairable

Replace CFF per WP 210 00*

c.

Nicks, scores, and scratches

Any number, any length, 0.016 in. (0.41 mm) deep, after removal of high metal

Not repairable

Replace CFF per WP 210 00*

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.) Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Surfaces for: - (cont.) d.

Dents

Any number smooth contour dents, 0.250 in. (6.35 mm) deep. Contour rate of change not to exceed 0.10 in. per 1.00 in. (2.54 mm per 25.4 mm)

Not repairable

Replace CFF per WP 210 00*

NO. 3 BEARING HOUSING AND NO. 3 BEARING HOUSING OIL SEAL SUPPORT 1. All Surfaces (unless otherwise specified) for: a.

Cracks

Not serviceable

Not repairable

Replace CFF per WP 210 00*

b.

Nicks, scores, and scratches

Any number, any length, 0.010 in. (0.25 mm) deep, after removal of high metal, if defect does not extend completely across sealing surface(s)

Not repairable

Replace CFF per WP 210 00*

c.

Dents

Any number smooth contour dents, 0.063 in. (1.60 mm) deep except on sealing surface(s). Contour rate of change not to exceed 0.10 in. per 1.00 in. (2.54 mm per 25.4 mm)

Not repairable

Replace CFF per WP 210 00*

2. Bearing Housing and Seal Support to Hub Mounting bolt for: a.

Loose or missing bolts

Not serviceable

Any amount

Tighten or replace bolts

Thread damage

Not serviceable

Not repairable

Replace bolt

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 416 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Bearing Oil Seal Support Gang Channels for: a.

Loose, missing, or high rivets

Not serviceable

Any amount

Tighten or replace rivet(s). Rivet head shall be flush or below face of flange

b.

Loss of nut, or nut selflocking quality

Not serviceable

Any amount

Replace nut or gang channel assembly*

4. Bearing Housing and Oil Seal Support Threaded Inserts for: a.

Loose or damaged inserts

Not serviceable

Any amount

Install new insert

* May be repairable. Contact GE for disposition of replaced parts.

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE RECOUP METERING SPACER SELECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 10 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 9 ................... 0 10 Blank ........... 0 Alphabetical Index Page

Subject High Pressure Recoup Metering Spacer Selection. ...........................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for selecting proper size high pressure (HP) recoup metering spacer to maintain engine within preferred operating range. The metering spacer is used to adjust engine HP recoup cavity pressure.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I LM2500+ SAC System Descriptions Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 Chapter 5 GEK 105054 WP 002 00 GEK 105055

3.

Support Equipment. None required.

4.

Consumable Material.

5.

Nomenclature

Part No./Specification

Thread Lubricant

GE Spec A50TF201 or MIL-T-5544

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Metering Spacer Metering Spacer Boss Seal Boss Seal

47-52 48-52 47-47 48-47

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Recoup Metering Spacer Selection. NOTE

•

Maintenance of engine HP recoup cavity pressure within defined limits is required to ensure No. 4B bearing life. Refer to GEK 105054, Chapter 5, for monitoring requirements.

•

During initial buildup and testing of engine, HP recoup cavity pressure is adjusted to acceptable limits using the proper size metering spacers. Periodic monitoring and, if necessary, an adjustment of metering spacers is required in service to maintain HP recoup cavity pressure within limits. Seal clearance leakage flow can change in service, particularly on new or recently overhauled engines, raising HP recoup pressure at a given set of conditions.

a.

Comply with all instructions contained in WP 002 00.

b.

Check and record part number of left and right metering spacers (4, figures 1 and 2). Determine corresponding spacer size from table 1. Left and right metering spacers should have same part number. If in doubt, remove metering spacers and establish actual orifice diameter(s).

c.

Use at least one of two available HP recoup pressure taps (5) located upstream measuring HP recoup pressure.

d.

Use average of left and right side HP recoup pressure readings if both measurements are recorded. Table 1. HP Recoup Metering Spacer Size Part No.

Orifice Diameter

L34518P03

0.298-0.302 inch

(7.57-7.67 mm)

L34518P04

0.398-0.402 inch

(10.11-10.21 mm)

L34518P05

0.498-0.502 inch

(12.65-12.75 mm)

L34518P06

0.598-0.602 inch

(15.19-15.30 mm)

L34518P07

0.698-0.702 inch

(17.73-17.83 mm)

L34518P08

0.798-0.802 inch

(20.37-20.27 mm)

L34518P09

0.898-0.902 inch

(22.81-22.91 mm)

L34518P10

0.998-1.002 inch

(25.35-25.45 mm)

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Left HP Recoup Spacer Configuration 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 417 00

Figure 2. Right HP Recoup Spacer Configuration 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00 7.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Adjustment Procedure For All GK, GV, PK, and PV Models. a.

During Engine Operation between 9000 and 9400 rpm gas generator speed and at PT5.4 of 40 psia (275.8 kPa) or above, record the following engine parameters at steady-state conditions: (1)

PT5.4 (Power turbine inlet pressure)

(2)

Ps3 (Compressor discharge pressure)

(3)

NGG (Gas Generator Speed)

(4)

P2 (Inlet pressure or barometer - inlet loss)

(5)

T2 (Inlet Pressure)

(6)

HPRCP (High pressure recoup pressure)

b.

Convert all recorded pressure measurements to absolute (psia), and convertall temperature measurements to Fahrenheit.

c.

Using worksheet (figure 3) or spreadsheet (figure 4), calculate whether orifice change is required. NOTE Off schedule variable stator vane (VSV) tracking with resultant NGG effects may make HP recoup orificesize calculation invalid. Ensure VSV schedule is in limits is operating region.

d.

If metering spacer change is required, always install identical orifice size metering spacer at both right and left side locations. Install with metering spacer part number visible from outside. These metering spacers are symmetrical and therfore, nondirectional.

e.

HP recoup metering spacers of less than 0.30 inch (7.6 mm) should not be required or used without prior consultation with manufacturer. CAUTION ALWAYS INSTALL IDENTICAL SIZE METERING SPACER AT BOTH RIGHT AND LEFT SIDE LOCATIONS, WITH IDENTIFICATION NUMBERS VISIBLE. FAILURE TO COMPLY MAY RESULT IN IMPROPER HP RECOUP FUNCTION AND POSSIBLE PART DAMAGE.

f.

Remove four bolts (9, figures 1 and 2) and nuts (8) securing manifold (1) and air tube (2) together.

g.

Remove and replace metering spacer (4) with required size.

h.

Lightly coat four bolt threads and contact faces of bolts (9) and nuts (8) with thread lubricant.

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 417 00

i.

Using four bolts (9) and nuts (8), secure manifold (1) and air tube (2). Tighten nuts to 5570 lb in. (6.3-7.9 N⋅m) of torque.

j.

Recheck orifice calculations at same power setting with new metering spacers installed in order to see if further adjustment is required.

k.

If calculated data or actual HP recoup pressure does not respond to predicted effects of orifice size change, perform the following steps: (1)

Validate data.

(2)

Check for leakage.

(3)

Check gage calibration.

(4)

If substeps (1) through (3) do not correct problem, contact GE Customer Service Representative.

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. High Pressure Recoup Orifice Selection Worksheet 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 417 00

Figure 4. Typical Excel Spreadsheet Based on Figure 3. Worksheet 9/(10 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE SYSTEM INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 14 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 14 ................. 1 Alphabetical Index Page

Subject Variable Stator Vane System Inspection. ..........................................................................

3

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1

GEK 105054 Volume II WP 418 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for inspection of the variable stator vane (VSV) system.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I Troubleshooting Operation and Maintenance Manual, Volume II Variable Stator Vane Actuator Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Variable Stator Vane Torque Shaft Replacement Variable Stator Vane Servovalve Replacement Variable Stator Vane Mechanism Replacement High Pressure Compressor Variable Stator Vane Replacement Variable Stator Vane Off-Schedule Inspection

GEK 105054 Chapter 9 GEK 105054 WP 100 00

3.

Support Equipment. None required.

4.

4.Consumable Material.

5.

2

WP 113 00 SWP 113 01 WP 114 00 WP 121 00 WP 209 00 WP 212 00 WP 414 00

Nomenclature

Part No./Specification

Silicone Rubber Adhesive (RTV-106) Red

GE Spec A15F6B6

Expendable Material. Not required.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Variable Stator Vane System Inspection. a.

Inspect high pressure compressor (HPC) stator case and VSV system per table 1 and figures 1 through 3. Table 1. VSV System Components Inspection

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. VSV Servovalve for: a.

Loose cable electrical connectors

Not serviceable

Any amount correctable by replacing or repairing electrical connectors

Replace or repair electrical connectors or replace cable per packager’s manual

b.

External leakage at tube fittings

Not serviceable

Any amount correctable by replacing attaching fitting, preformed packings, or retorquing of fittings

Replace preformed packings or replace servovalve per WP 121 00

c.

Cracked or broken hoses

Not serviceable

Not repairable

Replace hoses

d.

Loose or missing safety wire

Not serviceable

Not repairable

Replace safety wire

e.

Loose or missing hardware

Not serviceable

Any amount correctable by replacing or retorquing hardware

Replace missing hardware or retorque loose hardware

2. VSV Actuator for: a.

Loose cable electrical connectors

Not serviceable

Any amount correctable by replacing or repairing electrical/ cable connectors

Replace electrical cable per WP 113 00 or SWP 113 01

b.

External leakage at tube fittings

Not serviceable

Any amount correctable by replacing attaching fitting, preformed packings, or retorquing of fittings

Replace preformed packings or replace actuator per WP 100 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

3

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

2. VSV Actuator for: - (cont.) c. Leakage at 2 cc/min each rod or drain actuator can d.

e.

Loose or missing safety wire Missing or loose mount hardware

Not repairable

On-Site Corrective Action Replace VSV actuator per WP 100 00 or refer to GEK 105054, Chapter 9 Replace safety wire

Not serviceable

Not repairable

Not serviceable

Any amount correctable by replacing or retorquing hardware

Replace missing hardware or retorque loose hardware per WP 100 00

Not repairable

Replace mount bracket per WP 100 00 Retorque mount bolts per WP 100 00 Replace mount bracket per WP 100 00

3. VSV Actuator Mount Bracket for: a. Cracks Not serviceable

b.

Looseness

Not serviceable

Any amount

c.

Distortion

Not serviceable

Not repairable

4. VSV Torque Shaft for: a. Loose Not serviceable hardware b. Missing Not serviceable safety wire c. Bent or Not serviceable distorted input rods 5. VSV Torque Shaft Mounts for: a. Missing Not serviceable safety wire b. Loose Not serviceable hardware c. Cracks or Not serviceable distortion

4

On-Site Maximum Repairable Limits

Any amount Not repairable Not repairable

Retorque hardware per WP 114 00 Replace torque shaft per WP 114 00 Replace torque shaft per WP 114 00

Not repairable

Replace safety wire

Any amount

Retorque hardware per WP 114 00 Replace torque shaft per WP 114 00

Not repairable

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5A. VSV Torque Shaft Bearing for: a.

Fwd bearing

Total movement in the radial direction not to exceed 0.120 in. (3.05 mm). Replace bearings

Not repairable

Replace torque shaft per WP 114 00 and/or upgrade solid shaft to hallow shaft or replace bearing per Service Bulletin LM2500-IND-169

b.

Aft bearing

Total movement in the radial direction not to exceed 0.060 in. (1.52 mm). Replace bearings

Not repairable

Replace torque shaft per WP 114 00 and/or upgrade solid shaft to hallow shaft or replace bearing per Service Bulletin LM2500-IND-169

6. Connector Link for: a.

Cracks

Not serviceable

Not repairable

Replace connector link per WP 209 00

b.

Pinhole wear

Any amount of actuation arm movement less than 2 degrees. Measure per WP 414 00

Not repairable

Replace connector link per WP 209 00

c.

Wear at rod bearing mount hole

Fit between hole and bolt should not exceed 0.004 in. (0.10 mm) on diameter

Not repairable

Replace connector link per WP 209 00

d.

Wear at locating pin

0.010 in. (0.25 mm) diameter wire gage shall not pass through hole with pin in place

Not repairable

Replace connector link per WP 209 00

e.

Loose bolts

Not serviceable

Not repairable

Tighten or replace bolt or replace actuation ring if female thread is stripped per WP 209 00 Change 1

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

6. Connector Link for: - (cont.) f.

Nicks, dents, or scratches in link or input rod mount ears

Any number, 0.005 in. (0.12 mm) deep

Not repairable

Replace connector link per WP 209 00

g.

Connector link bushing wear

Not serviceable

Not repairable

Replace connector link per WP 209 00

7. Actuation Ring Segment for:

6

a.

Nut loose in actuation ring

Not serviceable

_

One spacer per actuation ring segment may be backed off until spacer head is against ring and locked into that position to prevent further wear of actuation ring. Silicone rubber adhesive may be applied around loose nut to stabilize it in ring. See figure 3

b.

Cracks in sidewalls, adjacent to nuts

Any number, 0.040 in. (10.2 mm) max in either direction circumferentially from nut centerline

_

Replace actuation ring segment per WP 209 00

c.

Cracks in ID and OD wall, between nut and end of ring

Two per end, from first nut to end of ring, if nut is tight and will not rotate

_

Replace actuation ring segment per WP 209 00

d.

All other cracks

Not serviceable

Not repairable

Replace actuation ring segment per WP 209 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

7. Actuation Ring Segment for: - (cont.) e.

Broken

Not serviceable

Not repairable

See Off-Schedule Variable Vane Inspection, WP 414 00

f.

Pinhole elongation

Any amount of actuation arm movement less than 2 degrees. Measure per WP 414 00

Not repairable

See Off-Schedule Variable Vane Inspection, WP 414 00

g.

Wear at hole of actuation ring spacer threaded insert

Relative motion between insert and ring segment shall not exceed 0.005 in. (0.12 mm). Use wire gage

Not repairable

Replace actuation ring segment per WP 209 00

h.

Wear of hole at metal bushing

Relative movement between insert and ring segment shall not exceed 0.005 in. (0.12 mm). Use wire gage

Not repairable

Replace actuation ring segment per WP 209 00

i.

Distortion (bent or twisted)

Not serviceable

Not repairable

Replace actuation ring segment per WP 209 00

j.

Nicks and dents

Any number, 0.015 in. (0.38 mm) deep, six per segment, or 0.030 in. (0.76 mm) deep, with a minimum separation of 2.00 in. (50.8 mm)

Not repairable

Replace actuation ring segment per WP 209 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

7

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

8. Actuation Ring Spacer for: a.

Loose or out of adjustment (Dim M, figure 1)

Not serviceable

Any amount

Adjust to obtain case to spacer clearance per WP 209 00

9. Vane Arm Sleeve for: a.

Worn

Nor serviceable

Not repairable

Replace actuation ring segment per WP 209 00

b.

Missing

Nor serviceable

Not repairable

Replace actuation ring segment per WP 209 00

c.

Cracked

Nor serviceable

Not repairable

Replace actuation ring segment per WP 209 00

Radial looseness: Any amount of radial movement, if bushings or washers are not missing. No metal-to-metal contact allowed

-

Remove case and replace bushings if metal-to-metal contact is noted

Side looseness: Any amount of side looseness 2 degrees or less. Measure per WP 414 00

-

See WP 414 00

10. Vane Assembly for (See figure 2.): a.

8

Looseness

b.

Bent actuation arms

Any number, bent 2 degrees or less. Measure per WP 414 00

-

See WP 414 00

c.

Misassembled actuation arms

Not serviceable

-

See WP 414 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

11. Vane Locking Nut for: a.

Looseness

Nut shall be tight, with at least three vane stud threads showing, as determined visually

Any amount

Replace nut if runon torque is less than 5 lb in. (0.6 N⋅m). If more than 5 lb in. (0.6 N⋅m), retorque nut to 86-95 lb in. (11.4-12.6 N⋅m). If locking nut is missing, see WP 414 00

b.

Loss of selflocking feature

5-40 lb in. (0.6-4.5 N⋅m) free running torque

Not repairable

Replace locking nut per WP 212 00

c.

Thread damage

Not serviceable

Not repairable

Replace locking nut per WP 212 00

12. Vane Actuation Arm for: a.

Security

Actuation arm shall be in place and secure

Any amount, if nut is in place and actuation arm is engaged in trunnion

Replace nut and tighten. If nut was not in place, see WP 414 00

b.

Distortion, bending, or pinhole elongation

Any amount, less than 2 degrees. Measure per WP 414 00

Not repairable

See WP 414 00

c.

Cracks

Not serviceable

Not repairable

Replace actuation arm

d.

Bent, distorted, or misaligned. Measure per WP 414 00

Not serviceable if more than ± 2 degrees

Not repairable

See WP 414 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

13. Spacer for: a.

Cracks

Not serviceable

Not repairable

Replace spacer

Shake vane while holding nut and listen for metal-tometal contact

Not repairable

Replace bushing

14. Glass Bushing for: a.

Wear

Figure 1. VSV Actuation Ring Spacer Dimension M

10

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 418 00

Figure 2. VSV Actuation System (Sheet 1 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

11

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. VSV Actuation System (Sheet 2 of 3) 12

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 418 00

Figure 2. VSV Actuation System (Sheet 3 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

13

GEK 105054 Volume II WP 418 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. Actuation Ring Spacer Nut Stabilized with RTV

14

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 419 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES THERMOCOUPLE PROBE (T5.4) INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 3 ................... 0 4 Blank ............. 0 Alphabetical Index Page

Subject Thermocouple Probe (T5.4) Inspection...............................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 419 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection of the T5.4 thermocouple probe.

2.

3.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Thermocouple Probe (T5.4) and Harness Replacement

GEK 105054 WP 002 00 WP 108 00

Support Equipment. Nomenclature

Part No./Specification

Multimeter

Local Purchase

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 419 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Thermocouple Probe (T5.4) Inspection. a.

Comply with all instructions contained in WP 002 00.

b.

Remove thermocouple harness from thermocouple probe per WP 108 00. NOTE Thermocouple probe may be left in turbine mid frame as long as probe junction is at 70°F (21.1°C).

c.

Remove thermocouple probe from turbine mid frame (TMF) per WP 108 00.

d.

Using multimeter, measure resistance across posts. Resistance from point A to point B (figure 1) shall be 0.44-0.83 ohms at 70°F (21.1°C). Discard thermocouple probes that do not meet specified reading.

e.

Using multimeter, measure resistance between posts and case. Resistance shall not be greater than 10 megohms.

f.

Install thermocouple probe into TMF per WP 108 00.

g.

Install thermocouple harness onto thermocouple probe per WP 108 00.

Figure 1. T5.4 Thermocouple Probe 3/(4 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES ACCESSORY GEARBOX INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 6 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 6 ................... 0 Alphabetical Index Page

Subject Accessory Gearbox Inspection. ........................................................................................... Accessory Gearbox Part Repair. ......................................................................................... Accessory Gearbox Part Replacement................................................................................

3 3 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection and repair of the LM2500+ Models GK and GV gas generator and Models PK and PV gas turbine accessory gearbox (AGB).

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II Accessory Gearbox Replacement Illustrated Parts Breakdown

GEK 105054 WP 206 00 GEK 105055

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Expandable Bushing Assembly

6-44

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

7.

Accessory Gearbox Inspection. a.

Remove AGB per WP 206 00.

b.

Inspect high pressure compressor (HPC) stator casing mounts and AGB mounting hardware per table 1 and figure 1.

Accessory Gearbox Part Repair. a.

8.

Part repair is limited to blending, cleaning, and replacing as noted during inspection.

Accessory Gearbox Part Replacement. a.

See table 1 for HPC stator casing mounts and mounting hardware replacement. Table 1. HPC Stator Casing Mounts and Mounting Hardware

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. HPC Stator Casing Mounts (1, figure 1) for: a.

Cracks

Not serviceable

Not repairable

Replace bracket*

b.

Nick, scores, and scratches

Not serviceable

Any number, 0.062 in. (1.5 mm) deep, 0.50 in. (12.7 mm) long, if length of damage does not exceed 4.00 in. (101.6 mm)

Completely blend out defect

c.

Pickup and high metal on mating surfaces

Not serviceable

Any amount

Remove high metal

d.

Thread for damage

Not serviceable

One complete internal thread may be missing

Replace insert

e.

Missing or loose paint

Not serviceable

Any amount

Remove loose paint.

f.

Bushing hole wear

0.725 in. (18.41 mm) ID max

Not repairable

Replace bushing

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. AGB Mounting Support and Mounting Hardware - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

2. Forward TGB Mounting Bracket (8) for: a. Cracks Not serviceable b. Nicks, scores, Not serviceable and scratches

c.

On-Site Maximum Repairable Limits

On-Site Corrective Action

Not repairable Any number, any length, 0.02 in. (0.5 mm) deep, after removal of high metal and blending Not repairable

Replace bracket* Remove high metal and blend to remove damage

Clevis hole 1.015 in. Replace bracket* wear (25.78 mm) ID 3. Right and Aft Mounting Bracket Assemblies (5 and 6) for: a. Cracks Not serviceable Not repairable Replace bracket* b. Nicks, scores, Not serviceable Any number, any Remove high metal and scratches length, 0.0625 in. and blend to remove (1.587 mm) deep, damage after removal of high metal and blending c. Flanged 0.005 in. (0.12 mm) Not repairable Replace bracket* bushing hole ID wear 4. Adjustable Link Assemblies (2 and 4) and Fixed Link Assembly (3) for: a. Cracks Not serviceable Not repairable Replace part* b. Link rod-end Not serviceable Any amount, if Clean and uniball for uniball is rust-free inspect seizure and swivels freely with finger-pressure after cleaning c. Link rod-end 0.005 in. (0.12 mm) Not repairable Replace rod-end uniball for radial clearance, assembly* wear 0.010 in. (0.25 mm) axial clearance d. Rod-end Not serviceable Cumulative length of Remove damage by thread 1/2 full thread may chasing thread damage be removed e. Turnbuckle Not serviceable Not repairable Replace part* distortion

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. AGB Mounting Support and Mounting Hardware - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Adjustable Link Assemblies (2 and 4) and Fixed Link Assembly (3) for: - (cont.) f.

Turnbuckle thread damage

Not serviceable

Cumulative length of 1/2 full thread may be removed

Remove damage by chasing thread

g.

Turnbuckle nicks, dents, or scratches

Any number, 0.062 in. (1.57 mm) deep

Not repairable

Replace part*

5. Expandable Bushing (7) for: a.

Shear bolt shank wear

0.0005 in. (0.012 mm) OD, min in contact area

Not repairable

Replace bolt*

b.

Shear bolt and nut thread damage

Not serviceable

Not repairable

Replace part*

c.

Loss of nut self-locking feature

Not serviceable

Not repairable

Replace nut*

d.

Wear of Not serviceable Not repairable expandable bushing * May be repairable. Contact GE for disposition of replaced parts.

Replace part*

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 420 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. AGB and Mounting Components 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE COMPONENTS INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 14 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 13.................. 0 14 Blank ........... 0 Alphabetical Index Page

Subject Power Turbine Stator Casings Inspection. ........................................................................ Turbine Rear Frame - Component Inspection. ..................................................................

3 9

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection of power turbine components.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II Six Stage Power Turbine Stator Casings Removal and Installation Power Turbine Assembly Replacement

GEK 105054

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

WP 218 00 WP 302 00

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Power Turbine Stator Casings Inspection. a.

Remove power turbine stator casings per WP 218 00.

b.

Inspect power turbine casings per figure 1 and table 1.

c.

Install power turbine stator casing per WP 218 00. Table 1. Power Turbine Stator Casings Inspection

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

CASING 1. Front Flange for: a.

Cracks extending from boltholes in any direction

Not serviceable

Replace power turbine per WP 302 00*

b.

Cracks, not extending from boltholes

Any number, 0.016 in. (0.40 mm) long, with 2.0 in. (50.8 mm) min spacing between cracks

Replace power turbine per WP 302 00*

c.

Nicks and scores

Any number, any length, 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face, after removal of high metal

Blend

2. Rear Flange for: a.

Cracks extending between boltholes

Not serviceable

Replace power turbine per WP 302 00*

b.

Cracks extending from boltholes to outer edge of flange

2 cracks per flange, if adjacent holes not cracked

Replace power turbine per WP 302 00*

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Stator Casings Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Rear Flange for: - (cont.) c.

Nicks, scores, and scratches

Any number, any length 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face, after removal of high metal

Blend

3. Horizontal Flanges for: a.

Cracks extending from boltholes to outer edge of flange

2 cracks per flange, if mating flange on other half of casing does not have cracks at same holes

Replace power turbine per WP 302 00*

b.

Nicks, scores, and scratches

Any number, any length, 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face, after removal of high metal

Blend

4. Casing Body (Except for vane mounting tracks) for: a.

Cracks

Any number, 0.062 in. (1.57 mm) long with 2.0 in. (50.8 mm) in spacing

Replace power turbine per WP 302 00*

b.

Nicks

Any number, 0.020 in. (0.50 mm) deep, after removal of high metal

Replace power turbine per WP 302 00*

c.

Scratches

Any number, any length, 0.010 in. (0.25 mm) deep

Replace power turbine per WP 302 00*

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Stator Casings Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Casing Body for: (Except for vane mounting tracks) for: - (cont.) d.

Dents

Any number, 0.125 in. (3.17 mm) deep, if assembly can be accomplished

Replace power turbine per WP 302 00*

e.

Distortion

Free state distortion acceptable, if assembly can be accomplished

Replace power turbine per WP 302 00*

5. Vane Mounting Tracks a.

Cracks

Not serviceable

b.

Nicks and scratches

Not serviceable

c.

Dents and distortion

Any amount, if vane can be installed

Replace power turbine per WP 302 00* Any amount

Blend

INTERSTAGE SEALS 1. Flange for: a.

Deformation

Not serviceable

Replace segment or replace power turbine per WP 302 00*

b.

Cracks or breakout at boltholes

Not serviceable

Replace segment or replace power turbine per WP 302 00*

c.

Cracks

Not serviceable

Replace segment or replace power turbine per WP 302 00*

d.

Nicks, dents, and scratches

Any number, 0.020 in. (0.50 mm) deep, after removal of high metal

Blend

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Stator Casings Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

0.005 in. (0.12 mm) deep

0.010 in. (0.25 mm) deep

Blend smooth

1. Flange for: - (cont.) e.

Wear

2. Honeycomb for: a.

Wear

Track not to exceed 0.150 in. (3.81 mm) max depth

Not repairable

Replace segment

b.

Damage caused by foreign objects or handling

Not to exceed 0.170 in. (4.31 mm) axially from forward edge or 10 percent of total circumferential length of stage, if damage does not extend into backing strips and there are no folded edges in honeycomb cells

Folded edges may be removed in any area of honeycomb up to 100% of each shroud segment

Remove folded edges of crushed cells

c.

Loose or missing cells

Not serviceable, except outer row of cells may be missing from both forward and aft edges, if there are no loose cells

Any amount of loose cells in forward and aft outer rows. On remainder of segment, 5 adjacent cells and no more than 3 such areas per segment

Remove loose cells

d.

Erosion of filler material

Any amount, as long as cells are still bonded

Not repairable

Replace segment

e.

Damage to extended honeycomb (stages 1, 2, and 3)

Any amount crushed even with backing strip and not loose

One cell row inside backing strip edge and 1/2 axial width

Remove loose metal

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Stator Casings Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Braze Joints for: a.

Cracks

Any number, 0.0625 in. (1.58 mm) long, 0.125 in. (3.17 mm) min spacing

Replace segment

SHROUDS l. Honeycomb for: a.

Wear

Track not to exceed 0.100 in. (2.5 mm) max depth

Not repairable

Replace segment

b.

Damage caused by foreign objects or handling

Not to exceed 10 percent of total circumferential length and not extending into backing strip if there are no folded edges on cells

Folded edges may be removed in any area of honeycomb up to 10% of each shroud segment

Remove folded edges of crushed cells

c.

Loose or unbonded cells

Not serviceable

5 adjacent cells and no more than 2 such areas per segment

Remove cells

d.

Erosion of braze filler material

Any amount, as long as cells are still unbonded

Not repairable

Replace segment

STAGE 1 NOZZLE INSULATOR COVER SEGMENTS 1. All Surfaces for: a.

Cracks

b.

Distortion

Any number, 1.0 in. (25.4 mm) long

Not repairable

Replace segments

Any amount, if Replace segments assembly can be accomplished * May be repairable, consult GE for disposition of replaced parts.

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

n

Figure 1. Power Turbine Stator Assembly 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 7.

Turbine Rear Frame - Component Inspection. a.

Inspect turbine rear frame (TRF) per figure 2 and table 2. Table 2. Turbine Rear Frame Inspection

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

NOTE Indications in parent metal (outside a weld/heat affected zone) are acceptable if the following conditions are met:· Indications are spaced greater than 0.50 inch (12.7 mm) apart.· Indications up to 0.030 inch (0.76 mm) long.· Indications 0.030-0.060 inch (0.77-1.52 mm) long, not interpreted as cracks. CASE 1. All Surfaces (unless otherwise specified) for: a.

Parent metal cracks

Not serviceable

Weld repairable in stiffening ribs, not repairable all other areas

Weld-repair stiffening ribs or replace power turbine per WP 302 00*

b.

Weld cracks

Any number, 0.062 in. (1.57 mm) long, if separation between cracks is 0.50 in. (12.7 mm)

Weld repairable in stiffening ribs, not repairable all other areas

Weld-repair stiffening ribs or replace power turbine per WP 302 00*

c.

Nicks, scores, and scratches

Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal, if they do not extend completely across sealing surface(s)

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Turbine Rear Frame Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Fore and Aft (Bolt Circle) Flanges for: a.

Cracks

2 boltholes, 180 degrees apart

Not repairable

Replace power turbine per WP 302 00*

b.

Deformation

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

3. D-Sump Manifold Mounting Pad (Strut No. 5) for: a.

Seating surface nicks, scores, and scratches

Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface

Not repairable

Replace power turbine per WP 302 00*

b.

Damaged threads

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

4. Overspeed Transducer Mounting Flanges for: a.

Cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

b.

Deformation

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

5. Clevis Mounts (Power Turbine) for: a.

Cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

b.

Bushing wear

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Turbine Rear Frame Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Clevis Mounts (Power Turbine) for: - (cont.) c.

Nicks, scores, and scratches

Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface(s)

Not repairable

Replace power turbine per WP 302 00*

d.

Dents

Any number, smooth contour dents 0.250 in. (6.35 mm) deep

Not repairable

Replace power turbine per WP 302 00*

6. Strut Fairing for: a.

Loose or missing rivets

Not serviceable

Any amount

Replace missing rivet(s)

b.

Cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

HUB 1. All Surfaces for: a.

Parent metal cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

b.

Weld cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

c.

Nicks, scores, and scratches

Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface(s)

Not repairable

Replace power turbine per WP 302 00*

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 421 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Turbine Rear Frame Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Hub to Sump Housing Flange Bolts for: a.

Loose or missing bolts and nuts

Not serviceable

Any number

Tighten or replace missing bolt and nut

Any number

Tighten screw. Screw shall be flush or below face of flange

3. Hub Gang Channels (Nut Assembly) for: a.

High or loose retaining screws

Not serviceable

* May be repairable, consult GE for disposition of replaced parts.

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 421 00

Figure 2. Turbine Rear Frame Subassembly Cutaway 13/(14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE STAGES 1 AND 6 ROTOR BLADE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 10 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 1 Alphabetical Index Page

Subject Power Turbine Rotor Blade Inspection. .............................................................................

3

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1

GEK 105054 Volume II WP 422 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package contains instructions for inspection of the LM2500+ Model PK gas turbine six stage power turbine stages 1 and 6 rotor blades.

2.

3.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Thermocouple Probe (T5.4) and Harness Replacement Power Turbine Inlet Pressure Probe (P5.4) Replacement Six Stage Power Turbine Casings Removal and Installation Six Stage Power Turbine Stage 1 Rotor Blade Replacement Power Turbine Assembly Replacement

GEK 105054 WP 002 00 WP 108 00 WP 112 00

WP 219 00 WP 302 00

Support Equipment. Nomenclature

Part No.

Borescope, Rigid Borescope, Flexible

2C6388G06 856A1321

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2

WP 218 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Power Turbine Rotor Blade Inspection. a.

Comply with all instructions contained in WP 002 00. NOTE Power turbine rotor stage 2 through stage 5 blades are not accessible for inspection without removal of power turbine stator casings.

b.

Inspect power turbine stage 1 rotor blades as follows: (1)

Prepare turbine mid frame (TMF) for borescope as follows: (a) Remove P5.4 pressure probe per WP 112 00. (b) Remove T5.4 thermocouples per WP 108 00. NOTE

Power turbine stage 1 rotor blade shroud inspection is not possible via borescope inspection. (2)

Using borescope, inspect power turbine stage 1 rotor blades. Manually rotate power turbine rotor to inspect of all stage 1 blades. Inspect power turbine stage 1 rotor blades per table 1 and figure 1.

(3)

If inspection of power turbine stage 1 rotor blade shrouds is required, proceed as follows: (a) Remove power turbine stator casings to expose power turbine rotor per WP 218 00. (b) Inspect power turbine stage 1 rotor blade shrouds per table 1 and figures 1 through 3.

c.

(4)

If removed, install P5.4 pressure probe per WP 112 00.

(5)

If removed, install T5.4 thermocouple probes per WP 108 00.

(6)

If removed, install power turbine stator casings per WP 218 00.

Inspect power turbine stage 6 rotor blades per following: (1)

Gain access to power turbine exhaust area per packager’s manual.

(2)

Visually inspect power turbine stage 6 rotor blades per table 1 and figures 1 through 3.

(3)

Inspect power turbine stage 6 rotor blade retainers per table 1 and figure 4.

(4)

Install exhaust duct access hatch per packager’s manual. Change 1

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

3

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

POWER TURBINE STAGE 1 ROTOR BLADES 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace power turbine blade per WP 219 00

2. Leading and Trailing Edges for: a.

Nicks

Areas X and Y: none. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation of 0.5 inch (13 mm)

Not repairable

Replace power turbine blade per WP 219 00

b.

Dents

Any number with no protrusions on opposite side. Five per blade with protrusion not to exceed 0.04 inch (1.0 mm) on opposite side

Not repairable

Replace power turbine blade per WP 219 00

c.

Corrosion and erosion

Entire blade: trace of surface corrosion acceptable

Missing material: not repairable

Replace power turbine blade per WP 219 00

3. Concave and Convex Surfaces for:

4

a.

Nicks

Areas X and Y: none. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation 0.25 inch (6.4 mm)

Not repairable

Replace power turbine blade per WP 219 00

b.

Dents

Any number, with no protrusion on opposite side

Not repairable

Replace power turbine blade per WP 219 00

c.

Corrosion and erosion

Entire blade: trace of surface corrosion acceptable

Extensive corrosion: not repairable

Replace power turbine blade per WP 219 00

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

POWER TURBINE STAGE 1 AND STAGE 6 ROTOR BLADE SHROUDS 1. Blade Shrouds for: a.

Overlapping

Any number, provided blade has not shifted axially

Any number may be relatched

Replace power turbine per WP 302 00*

Unlatching

Any number, provided blade has not shifted axially

Any number may be relatched

Replace power turbine per WP 302 00*

Interlock wear

0.020 inch (0.51 mm)

0.100 inch (2.54 mm)

Replace power turbine per WP 302 00*

POWER TURBINE STAGE 6 ROTOR BLADES 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace power turbine per WP 302 00*

2. Leading and Trailing Edges for: a.

Nicks

Areas X and Y: same as balance of blade. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation of 0.5 inch (13 mm)

Not repairable

Replace power turbine per WP 302 00*

b.

Dents

Areas X and Y: same as balance of blade. Balance of blade: any number with no protrusions on opposite side. Five per blade with protrusion not to exceed 0.04 inch (1.0 mm) on opposite side

Not repairable

Replace power turbine per WP 302 00*

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Leading and Trailing Edges for: - (cont.) c.

Corrosion and erosion

Areas X and Y: same as balance of blade. Balance of blade: any amount

3. Concave and Convex Surfaces for: a.

Nicks

Areas X and Y: same as balance of blade. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation 0.25 inch (6.4 mm)

Not repairable

Replace power turbine per WP 302 00*

b.

Dents

Areas X and Y: same as balance of blade. Balance of blade: any number, with no protrusion on opposite side

Not repairable

Replace power turbine per WP 302 00*

c.

Corrosion and erosion

Areas X and Y: same as balance of blade. Balance of blade: any amount

BLADE RETAINERS 1. Stage 6 Blade Retainers for: a.

Unbending

Not to exceed 30 degrees away from blade

Not repairable

Replace power turbine per WP 302 00*

b.

Axial movement, forward or aft

0.100 inch (2.54 mm)

Not repairable

Replace power turbine per WP 302 00*

* May be repairable. Consult GE for disposition of replaced parts.

6

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 422 00

Figure 1. Power Turbine Blade Inspection Areas Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

7

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. Power Turbine Blade Shrouds 8

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 422 00

Figure 3. Power Turbine Rotor Blade Shroud Inspection Areas Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9

GEK 105054 Volume II WP 422 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 4. Stage 6 Power Turbine Blade Retainer Inspection Criteria 10

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR STATOR CASINGS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 14 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 13 ................. 0 14 Blank ........... 0 Alphabetical Index Page

Subject High Pressure Compressor Stator Casings Inspection. ....................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure compressor (HPC) stator casings.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Replacement High Pressure Compressor Fixed Stator Vane Replacement

GEK 105054 WP 211 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

WP 212 00 WP 214 00

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Compressor Stator Casings Inspection. a.

Remove HPC stator casings per WP 211 00.

b.

Remove variable stator vanes (VSV) per WP 212 00.

c.

Remove fixed stator vanes per WP 214 00.

d.

Inspect forward HPC stator casings per table 1 and figure 1.

e.

Inspect aft HPC stator casing per table 1 and figure 2. Table 1. HPC Stator Casings And Components

Inspect

On-Site Maximum Serviceable Limits

HPC FORWARD STATOR CASE 1. Horizontal Flanges for: a. Cracks Not serviceable, except; max of 3 per flange per casing half, emanating from boltholes outward to edge of flange b. Nicks, Any number, 0.015 scratches, in. (0.38 mm) deep, dents, or if defect does not gouges on extend completely mating across mating surface flange 2. Circumferential Flanges for: a. Cracks Not serviceable, except; max of 3 per flange per casing half, emanating from boltholes outward to flange outside dia (OD), one per hole

On-Site Maximum Repairable Limits

On-Site Corrective Action

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

Any number, 0.030 in. (0.76 mm) deep

Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

2. Circumferential Flanges for: - (cont.) b. Nicks, Any number, 0.015 scratches, in. (0.38 mm) deep, dents, and if defect does not gouges extend completely across mating surface 3. Casing ID Surface for: a. Cracks Not serviceable

b.

Rotor rub marks

0.025 in. (0.63 mm) deep. Coating shall be fully bonded in all areas.

On-Site Maximum Repairable Limits

On-Site Corrective Action

Any number, any length, 0.030 in. (0.76 mm) deep

Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

Not repairable

NOTE Perform following measurements after removal of metal buildup. c.

Rotor rub into parent metal

1. Any amount to 0.010 in. (0.25 mm) deep or 0.055 (1.39 mm) remaining wall thickness in area from forward flange to stage 7 vane slot 2. Any amount to 0.020 in. (0.50 mm) deep in area from stage 7 vane slot to aft flange

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

3. Casing ID Surface for: - (cont.) d. Nicks and Any number, 0.025 scratches in. (0.63 mm) deep, 1.0 in. (25.4 mm) long. Max of 10, 0.025 in. (0.63 mm) deep, any length e. Gouges on Any number, 0.010 areas between in. (0.25 mm) deep, T-slots and 0.25 in. (6.3 mm) around vane long bores f. Spalling or Up to 5.0 square in. chipping of (32 cm2) per abradable rub stage missing, if adjacent remaining coat material is fully bonded to parent metal (no evidence of peeling). Any amount of coating may be missing in area 4.603 in. (116.91 mm) from face of front flange 4. Variable Vane Bore Mating Surfaces for: a. Nicks and 0.010 in. (0.25 mm) scratches deep, if not over 30 percent of area is affected, and not over 50 percent of vane bores in each stage are affected and after removal of high metal

On-Site Maximum Repairable Limits

On-Site Corrective Action Remove high metal

Any number 0.020 in. (0.50 mm) deep, 0.25 in. (6.3 mm) long

Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

0.0312 in. (0.792 mm) deep, if not over 20 percent of area is affected, and not over 50 percent of vane bores in each stage are affected.

Replace HPC stator casings as matched set per WP 211 00*

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

5. Mounting Pads for: a. Insert Not serviceable damage 6. Manifold (Stage 9) for: a. Cracks Not serviceable

b

Dents

3 per casing half, 0.25 in. (6.3 mm) deep, with min spacing of 2.0 in. (50.8 mm), and at least 0.75 in. (19.0 mm) from any weld. 0.050 in. (1.27 mm) min radius at bottom of dent 7. Casing Externally for: a. Cracks in ribs Not serviceable (excluding manifold ribs)

On-Site Maximum Repairable Limits

On-Site Corrective Action

Any number

Replace insert

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

Not repairable

3 per casing, 0.5 in. (12.7 mm) long, if spacing between each defect exceeds 3.0 in. (76.2 mm)

Bench with 0.030 in. (0.76 mm) min radius tool to max depth of 0.0156 in. (0.396 mm) and inspect, or replace HPC stator casings as matched set per WP 211 00*

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

7. Casing Externally for: - (cont.) b. Cracks in Not serviceable casing skin

On-Site Maximum Repairable Limits

On-Site Corrective Action

Any number, 0.5 in. (12.7 mm) long, if spacing between each defect exceeds 3.0 in. (76.2 mm)

Bench with 0.030 in. (0.76 mm) min radius tool to max depth of 0.0156 in. (0.396 mm) and inspect. No indications allowed, or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

c.

Bulges

Not serviceable

Not repairable

d.

Pits

Not repairable

e.

Nicks or scratches

Any number, up to 0.125 in. (3.17 mm) diameter and 0.0156 in. (0.396 mm) deep Any number, 0.0156 in. (0.396 mm) deep 1.0 in. (25.4 mm) long, with 0.030 in. (0.76 mm) min radius at bottom except in area of vane T-slots where remaining casing thickness shall not be less than 0.060 in. (1.52 mm) at stage 10 and 0.090 in. (2.28 mm) at stage 11

Any number, 0.030 in. (0.76 mm) deep, 1.5 in. (38.1 mm) long, with 0.030 in. (0.76 mm) min radius at bottom except in area of vane T-slots where remaining casing thickness shall not be less than 0.060 in. (1.52 mm) at stage 10 and 0.090 in. (2.28 mm) at stage 11

Remove high metal. Blend out nicks or scratches with 0.030 in. (0.76 mm) min radius tool, or replace HPC stator casings as matched set per WP 211 00*

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

7. Casing Externally for: - (cont.) f. Local surface Not serviceable discoloration (blue) due to blade tip rub g. Wear cause by 0.025 in. (0.63 mm) actuation ring deep, after removal spacer of high metal and sharp edges KEY 1. HPC Upper Stator Casing Key for: a. Damage Any amount, if proper assembly can be performed and key does not protrude above casing flange HPC AFT STATOR CASE 1. Horizontal Flanges for: a. Cracks Not serviceable except max of one per flange per casing half emanating outward from boltholes to flange edge b. Nicks, dents, Any number to scratches, and 0.0312 in. (0.792 gouges mm) deep, after removal of high metal, if defect does not completely cross mating surface

On-Site Maximum Repairable Limits

On-Site Corrective Action

Not repairable

Replace HPC stator casings as matched set per WP 211 00

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

Not repairable

Replace part

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

Remove high metal with fine emery cloth or replace casings as matched set*

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

2. Forward and Aft Circumferential Flanges for: a. Cracks Not serviceable Not repairable

b.

Any number to 0.0312 in. (0.792 mm) deep, after removal of high metal, if defect does not completely cross mating surface 3. Casing ID Surface for: a. Cracks Not serviceable

b.

c.

d.

Nicks, dents, scratches, and gouges

Not repairable

Nicks, scratches, scores, or gouges on vane retaining lips and lands Rotor rub marks

Any number 0.0312 in. (0.792 mm) deep, after removal of high metal

Not repairable

Any amount, if bond coat still remaining

Not repairable

Spalling or chipping of abradable rub coat

Any amount within 0.125 in. (3.17 mm) of edge and 10 percent of remaining area

Not repairable

On-Site Corrective Action Replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth or replace HPC stator casings as matched set per WP 211 00*

Replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth, or replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth, or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

3. Casing ID Surface for: - (cont.) e. Gouges on 1.0 square in. (6.5 area other cm2) per circumferential than fixed land vane retaining lips

4. Casing Externally for: a. Cracks in skin Not serviceable

b.

Nicks, scratches, and dents

c.

Bulges

Any number, 0.25 in. (6.3 mm) long, 0.0156 in. (0.396 mm) deep, after removal of high metal Not serviceable

5. Manifold (Stage 13) for: a. Cracks in Not serviceable weld or parent metal b. Nicks and Any number to scratches 0.0156 in. (0.396 mm) deep

On-Site Maximum Repairable Limits

On-Site Corrective Action

One gouge 0.035 in. (0.88 mm) deep, 1.0 in. (25.4 mm) long per stage per casing half, and 3 gouges, 0.015 in. (0.38 mm) deep, 6.0 in. (152.4 mm) long per stage casing half

Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Bench with 0.030 in. (0.76 mm) min radius tool or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

Not repairable

Not repairable

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

5. Manifold (Stage 13) for: - (cont.) c. Dents 3 per casing half, 0.25 in. (6.3 mm) deep, 2.0 in. (50.8 mm) apart and at least 0.75 in. (19.0 mm) from any weld with min radius of 0.050 in. (1.27 mm) at bottom of dent KEY 1. HPC Upper Stator Casing Key for: a. Damage Any amount, if proper assembly can be performed and key does not protrude above casing flange

On-Site Maximum Repairable Limits

On-Site Corrective Action

Not repairable

Replace HPC stator casings as matched set per WP 211 00*

Not repairable

Replace part

*May be repairable, consult GE for disposition of replaced parts.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 423 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. HPC Forward Stator Casing 12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 423 00

Figure 2. HPC Aft Stator Casing 13/(14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR ROTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 16 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 16 ................. 0

Alphabetical Index Subject

Page

High Pressure Compressor Rotor Inspection..................................................................... 3 High Pressure Compressor Rotor Blade General Repair.................................................. 7 High Pressure Compressor Rotor Blisk and Stage 1 Blade Repair.................................. 11 High Pressure Compressor Stage 2 Blade Repair. ............................................................ 13 High Pressure Compressor Stages 3 through 16 Blade Repair. ....................................... 15

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for inspecting the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure compressor (HPC) rotor.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Rotor Blades Replacement

GEK 105054 WP 211 00 WP 215 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Compressor Rotor Inspection. a.

Expose HPC rotor per WP 211 00.

b.

Refer to table 1 and figure 1 for inspection limits. Table 1. Compressor Spools, Disks, and Blades On-Site Maximum Serviceable Limits

Inspect

SPOOLS AND DISKS 1. All Areas for: a. Cracks Not serviceable (except seals) 2. Front Air Seal Serration for: a. Pits, nicks, Not serviceable dents, and scratches b.

Bending

Not serviceable

3. Interstage Air Seal Serrations for: a. Pits, nicks, Any number, 0.005 dents, and in. (0.12 mm) deep. scratches Any number, 0.03 in. (0.76 mm) deep, 0.050 in. (1.27 mm) long, separated by 15 degrees and 5 degrees from blends on adjacent teeth b. Bending Not serviceable

On-Site Maximum Repairable Limits

On-Site Corrective Action

Not repairable

Replace gas generator

Five per tooth. Total areas removed, not to exceed 0.15 sq. in. (0.96 cm2) per tooth Five per tooth. Total areas removed, not to exceed 0.15 sq. in. (0.96 cm2) per tooth

Blend

Three per 6.00 in. (152.4 mm) of circumference on each tooth, 0.090 in. (2.28 mm) deep, 0.050 in. (1.27 mm) long

Blend

One per tooth, 1.00 in. (25.4 mm) long

Replace gas generator

Blend

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Spools, Disks, and Blades - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Journal OD for: a.

Nicks, scores, and scratches

Any number, 0.020 in. (0.50 mm) wide, 0.003 in. (0.07 mm) deep, after removal of high metal

Any number, 0.010 in. (0.25 mm) deep

Remove high metal

5. Oil Seal Serrations for: a.

Nicks and dents on OD

Not serviceable

Five per each serration, 0.045 in. (1.14 mm) deep, 0.50 in. (12.7 mm) long after blending. One serration, 1.00 in. (25.4 mm) long for depth of serration

Blend

b.

Cracks originating from OD

Not serviceable

Five per each serration, depth of serration

Blend. Width of blend to be two times depth of crack

Not serviceable

Threads shall be free of all pickup metal. Cumulative length of 50% complete thread can be removed

Remove pickup metal. Blend to original finish

0.19 square in. (1.2 cm2), not extending into flow path

Blend off bent up corners. Do not leave thin edge. Break all thin edges and blend smooth

6. External Threads for: a.

Damage

7. Stages 1 and 2 Disk OD Airflow Surface for: a.

Tang corner tip curl

0.13 square in. (0.83 cm2), not extending into flow path

8. OD Surfaces, Stages 3 through 13, Abradable Rub Coat for: a.

Missing spray coating

Any amount

-

-

b.

Vane rub

Any amount, if parent metal is not rubbed

Not repairable

Replace gas generator

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Spools, Disks, and Blades - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

9. OD Surfaces, Stages 14 through 16, Abradable Rub Coat for: a.

Vane rub, nicks or scores, and scratches between stages 13 and 14

Any amount, if parent metal is not rubbed and not exceeding 0.005 in. (0.12 mm) depth per stage

Not repairable

Replace gas generator

b.

Vane rub, nicks or scores, and scratches

Any amount, if parent metal is not rubbed and not exceeding 0.005 in. (0.12 mm) depth per stage

Not repairable

Replace gas generator

10. OD Surfaces, Other than Abradable Rub Coat, for: a.

Pits, nicks, scores, and scratches

Any number, 0.003 in. (0.07 mm) deep, if not more than 25 percent of total area is affected

-

-

Any number, 0.003 in. (0.07 mm) deep, after removal of high metal

Any number, 0.005 in. (0.12 mm) deep. Up to 25 percent of area may be blended

Blend

11. All Other Surfaces: a.

Pits, nicks, scores, and scratches

HIGH PRESSURE COMPRESSOR ROTOR BLADES 1. Repair damage to airfoils to limits specified in paragraphs 7, 8, 9, and 10 of this work package. For damage/wear to all other areas of blade, replace blade.

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. HPC Rotor 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 7.

High Pressure Compressor Rotor Blade General Repair WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. NOTE HPC rotor stages 1 through 14 blades are made of titanium. a.

For initial removal of material, file or blend in longitudinal direction, parallel with airfoil length, using smooth file, not over 8.0 inches (203 mm) long, or emery cloth.

b.

Power tools may be used for initial heavy removal of material. NOTE All blend repair and polishing shall be done in direction parallel with blade leading or trailing edges. Do not use power tools for final polish or finish blending.

c.

Final blend and polish to depth of 0.020-0.030 in. (0.51-0.76 mm) shall be accomplished by hand.

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

d.

Using medium stone, blend any areas having been blended with file or emery cloth and areas containing small nicks and dents.

e.

Using fine emery cloth and/or fine abrasive stone, polish blended area until finish looks and feels like original.

f.

Blend any HPC rotor blade having trailing edge cross-section of less than 0.010 in. (0.25 mm) until it is at least 0.010 in. (0.25 mm).

g.

Blend HPC rotor blades leading and trailing edges (figure 2), per limits for stage of HPC rotor blade being repaired, as follows:

h.

(1)

Do not exceed maximum repairable limits for HPC rotor blade being repaired.

(2)

Minimum blend radius (Dim B) will be eight times the depth of blend (Dim A).

(3)

Blend HPC rotor blade leading edges to as near original configuration as possible.

(4)

Blend HPC rotor blade trailing edges to remove all sharp edges.

(5)

Contour blended edges.

Blend HPC rotor blade corners, per limits for stage of HPC rotor blade being repaired, as follows: (1)

Whenever possible, remove damage on leading and/or trailing edge corners by blending smooth radius.

(2)

Remove as little metal as possible.

(3)

Do not exceed limits for HPC rotor blade stage.

(4)

If both corners are damaged, blend out damage.

(5)

If only one corner is damaged, blend out damage at leading or trailing edge corner. CAUTION

DO NOT STRAIGHTEN BENT TIPS. i.

Blend HPC rotor blade squealer tips (figure 3), per limits for stage of HPC rotor blade being repaired, as follows: (1)

Accept HPC rotor blade tips bent less than 15 degrees if there are no cracks.

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

j.

GEK 105054 Volume II WP 424 00

(2)

Remove HPC rotor blade tips bent over 15 degrees by blending.

(3)

Blend nicks, gouges, dents, and cracks by removing damaged metal.

(4)

Cracks shall be completely removed by blending.

(5)

No cracks, burrs, or rolled metal are allowed and shall be completely removed by deburring/blending.

(6)

No heat discoloration allowed. Replace blade(s) per WP 215 00.

Inspect blended area by spot fluorescent-penetrant (FPI) method after blending. No cracks allowed.

Figure 2. HPC Rotor Blade Leading and Trailing Edge Blending

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. HPC Rotor Blade Tip Blending

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 8.

High Pressure Compressor Rotor Blisk and Stage 1 Blade Repair. WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor blisk and stage 1 blades (figure 4) as follows: (1)

Blend maximum of 20 percent of HPC rotor blisk and stage 1 blade airfoils to limits shown.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required. Minimum tip chord remaining shall be 2.439 in. (61.95 mm).

(3)

Blend limit of Dim W shall be 0.30 in. (7.6 mm) maximum.

(4)

Blend limit of Area D shall be 0.05 in. (1.2 mm) maximum.

(5)

Blend limit of Area B shall be 0.02 in. (0.5 mm) maximum.

(6)

After blending, spot FPI blended areas. No cracks are allowed.

(7)

If HPC rotor stage 1 blades limits are exceeded, replace HPC rotor stage 1 blades per WP 215 00.

(8)

If blisk limits are exceeded, replace gas generator per WP 301 00.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 4. HPC Rotor Blisk and Stage 1 Blade Blending

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 9.

High Pressure Compressor Stage 2 Blade Repair. WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor stage 2 blades (figure 5) as follows: (1)

Blend maximum of 20 percent of HPC rotor stage 2 blade air foils to within limits. Blend leading edges, only if required to meet section contour.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required. Minimum tip chord remaining shall be 2.33 in. (59.2 mm).

(3)

Blend limits of Dim Y and Dim Z added together shall be 0.30 in. (7.6 mm) maximum.

(4)

Blend limit Dim X shall be 2.15 in. (54.6 mm) maximum.

(5)

Blend limit of Dim W shall be 0.30 in. (7.6 mm) maximum.

(6)

Blend limit of Area B shall be 0.02 in. (0.5 mm) maximum.

(7)

After blending, spot FPI blended area. No cracks allowed.

(8)

If limits are exceeded, replace HPC rotor stage 2 blades per WP 215 00.

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 5. HPC Rotor Stage 2 Blade Blending

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 10. High Pressure Compressor Stages 3 through 16 Blade Repair. WARNING

TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor stages 3 through 16 blades (figure 6) as follows: (1)

Blend maximum of 20 percent of HPC rotor blade airfoils in affected stage to within limits. Blend leading edges, only if required to meet section contour.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required.

(3)

If damage leaves tip section (Dim Y or Dim Z) of less than 0.156 in (3.96 mm), remove section.

(4)

Dim U shall be measured from line between fillet radii R1 and bottom of damaged area. Blend limit for Dim U shall be 0.03 in. (0.7 mm).

(5)

Minimum radius (R1) shall be 0.080 in.

(6)

Maximum corner radius (R2) shall be 1/10 of blade chord length.

(7)

Blend limits of Dim Y and Dim Z shall be added together to find Dim YZ. Maximum Dim YZ shall be per table 2.

(8)

Dim F shall be per table 2.

(9)

Blend limit for Area B shall be 0.020 in. (0.5 mm) maximum.

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 424 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

(10) Blend limit for Dim W shall be 0.30 in. (7.6 mm) maximum. (11) If limits are exceeded, replace HPC rotor blade per WP 215 00. Table 2. Stages 3 through 16 Blade Limits Stage 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2.00 in. 0.75 in. 0.50 in. 0.25 in. 1.0 in. 1.0 in. 0.75 in. 0.75 in. 0.75 in. 0.50 in. 0.50 in. 0.25 in. 0.25 in. 0.25 in.

Dim F (50.8 mm) (19.0 mm) (12.7 mm) (6.3 mm) (25.4 mm) (25.4 mm) (19.0 mm) (19.0 mm) (19.0 mm) (12.7 mm) (12.7 mm) (6.3 mm) (6.3 mm) (6.3 mm)

0.30 in. 0.30 in. 0.28 in. 0.28 in. 0.24 in. 0.24 in. 0.22 in. 0.22 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in.

Dim YZ (7.6 mm) (7.6 mm) (7.1 mm) (7.1 mm) (6.0 mm) (6.0 mm) (5.5 mm) (5.5 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm)

Figure 6. HPC Rotor Stages 3 through 16 Blade Blending 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES SINGLE ANNULAR COMBUSTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 8 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 7 ................... 0 8 Blank ............. 0 Alphabetical Index Page

Subject Single Annular Combustor Inspection. ..............................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, single annular combustor.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II Single Annular Combustor Replacement High Pressure Turbine Stage 1 Nozzle Inspection High Pressure Turbine Stage 2 Nozzle Inspection

GEK 105054 WP 203 00 WP 427 00 WP 428 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Single Annular Combustor Inspection. a.

Inspect single annular combustor per table 1 and figure 1. Table 1. Single Annular Combustor Inspection

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Surfaces for: a.

Discoloration

Serviceable

_

_

b.

Carbon accumulation

Any amount

_

_

2. Riveted Joints for: a.

Loose, cracked, or missing rivets

Six nonadjacent rivets in each rivet circle may be loose, cracked, or missing

Not repairable

Replace combustor per WP 203 00

b.

Cracked or torn rivet holes in cowl and skirts

One crack 0.030 in. (0.76 mm) long per hole; 20 holes max per rivet circle

Not repairable

Replace combustor per WP 203 00

3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: a.

Axial cracks

Any number, less than 1.25 in. (31.7 mm) long; one crack greater than 1.25 in. (31.7 mm) in each swirl cup location, max length of 2.25 in. (57.1 mm) not to exceed eight per dome

Not repairable

Replace combustor per WP 203 00

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Single Annular Combustor Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: - (cont.) b.

Circumferential cracks

Any number, less than 0.75 in. (19.0 mm) long, five cracks 2.25 in. (57.1 mm) long separated by 1.00 in. (25.4 mm) from any other crack greater than 0.75 in. (19.0 mm) long

Not repairable

Replace combustor per WP 203 00

4. Trumpet and Swirl Cup (Excluding Overhung Surfaces) for: a.

Cracks

Four cracks, 1.25 in. (31.7 mm) long per item; any number less than 0.50 in. (12.7 mm) long

Not repairable

Replace combustor per WP 203 00

b.

Distortion of trumpet

Any amount

_

_

5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: a.

Burn through or missing metal of nonoverhung surfaces

Any amount less than 90 degrees maximum burn through of domeplate around any one swirl cup. Burn through limited to eight areas per dome, maximum size 1.0 in. (25.4 mm) by 1.0 in. (25.4 mm). Any amount of trumpet distress is allowed

Not repairable

Replace combustor per WP 203 00

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Single Annular Combustor Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: - (cont.) NOTE Burn through in combustor dome will reduce the cooling flow to the high pressure turbine (HPT) nozzles vanes. Inspect HPT stage 1 and 2 nozzle vanes per WP 427 00 and WP 428 00. b.

Burn through or missing metal of overhung surfaces

Any amount

_

_

6. Igniter sleeve for: a.

Cracks

Any number, 0.25 in. (6.3 mm) long

Not repairable

Replace combustor per WP 203 00

b.

Burns

0. 13 in. (3.3 mm) burn permissible on bottom of ferrule (flame side)

Not repairable

Replace combustor per WP 203 00

c.

Wear

0.75 in. (19.0 mm) inside diameter (ID) max

Not repairable

Replace combustor per WP 203 00

Not repairable

Replace combustor per WP 203 00

7. Inner and Outer Liners for: a.

Circumferential cracks

Any number, noninterconnecting cracks per band, each 1.00 in. (25.4 mm) long separated by 2.00 in. (50.8 mm) from any other crack. Total length of all circumferential cracks in any band shall not exceed 7.00 in. (177.8 mm)

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 425 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Single Annular Combustor Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

7. Inner and Outer Liners for: - (cont.) b.

Axial cracks

Six cracks per liner, max length not to exceed 2 adjoining bands (3 rows of cooling holes), any number of cracks 1.25 in. (31.7 mm) per band. Axial and circumferential cracks, 1.00 in. (25.4 mm) or longer shall have minimum separation of 2.00 in. (50.8 mm)

Not repairable

Replace combustor per WP 203 00

c.

Burns

Six burned through areas of 0.75 in. (19.0 mm) by 1.00 in. (25.4 mm) per liner separated by 2.50 in. (63.5 mm)

Not repairable

Replace combustor per WP 203 00

d.

Distortion

Any amount, within 0.50 in. (12.7 mm) from original contour

Not repairable

Replace combustor per WP 203 00

8. Cowl for: a.

Burns at fuel nozzle eyelet (fuel nozzle removed)

Accept three burn through areas of 0.25 in. (6.3 mm) by 1.00 in. (25.4 mm)

Not repairable

Replace combustor per WP 203 00

b.

Cracks

Any number, 0.25 in. (6.3 mm) long

Not repairable

Replace combustor per WP 203 00

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 425 00

Figure 1. Single Annular Combustor 7/(8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE ROTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 36 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 35 ................. 0 36 Blank ........... 0 Alphabetical Index Page

Subject High Pressure Turbine Rotor Inspection. ..........................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure turbine (HPT) rotor.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 2 Nozzle Assembly Replacement High Pressure Turbine Rotor Blade Replacement

GEK 105054 WP 201 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

SWP 201 01 WP 202 00

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Turbine Rotor Inspection. a.

Remove HPT rotor per WP 201 00.

b.

Remove HPT stage 2 nozzle per SWP 201 01.

c.

Inspect HPT rotor per tables 1 and 2 and figures 1 through 7. Table 1. HPT Rotor On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

FORWARD SHAFT ROTATING AIR SEALS 1. All Areas (except serrations) for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

b.

Nicks, dents, and scratches

Any number, 0.015 in. (0.38 mm) deep after removal of high metal

Not repairable

Replace HPT rotor per WP 201 00

Not serviceable

Any amount

Remove high metal

2. Seal Serrations for: a.

Turned metal

NOTE

•

Maximum individual or cumulative length of blends on any one tooth of seal shall not exceed 5.0 in. (127 mm).

• Total cumulative length of all blends on six serrations per rotating

air seal shall not exceed 16 in. (406.4 mm), or forward tooth on forward rotating air seal may be removed 100 percent if cumulative length of all blends on remaining seal teeth do not exceed 8 in. (203.2 mm).

b.

•

Measurements to be made at outside diameter of serrations (including blend radius).

•

Do not leave serration sections less than 1.0 in. (25.4 mm) long between blends.

Cracked or cracked out serrations

Not serviceable

Any number may be blended out if completely removed between limits of preceding NOTE and figure 2

Blend and inspect for cracks

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Seal Serrations for: - (cont.) c.

Nicks and dents

Any number, 0.02 in. (0.50 mm) deep, after removal of high metal

Any number may be blended out if completely removed between limits of preceding NOTE and figure 2

Blend and inspect for cracks

d.

Scratches

Any number, 0.030 in. (0.76 mm) deep, after removal of high metal

Any number may be blended out if completely removed between limits of preceding NOTE and figure 2

Blend and inspect for cracks

e.

Bending

Not serviceable

Any length may be straightened max of 0.13 in. (3.3 mm) axially

Straighten with hand tools. Serration shall not be overbent and rebent. Inspect for cracks

FORWARD SHAFT NOTE Limits are for areas aft of 13 in. (330.2 mm) from forward shaft front face. 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Splines for: a.

High metal

Not serviceable

Any amount

Remove high metal

b.

Nicks and dents

Any number, 0.03 in. (0.76 mm) wide by 0.25 in. (6.3 mm) long, after removal of high metal. None allowed in root radii. Total area of nicks and dents on each tooth not to exceed 15 percent of that tooth area

Not repairable

Replace HPT rotor per WP 201 00

c.

Scratches

Any number, 0.020 in. (0.50 mm) deep, 0.06 in. (1.5 mm) wide, 0.63 in. (16.0 mm) long, after removal of high metal. None allowed in root radii. Total area of scratches on each tooth not to exceed 10 percent of that tooth area

Not repairable

Replace HPT rotor per WP 201 00

3. Pilot for: a.

Nicks and dents

Any number, 0.060 in. (1.52 mm) deep, after removal of high metal

Not repairable

Replace HPT rotor per WP 201 00

b.

Pick up and high metal

Not serviceable

Any amount

Remove high metal

c.

Scratches

Any number, any length, 0.010 in. (0.25 mm) deep, any length

Any number if not more than 13 percent of surface is affected

Blend to remove damage

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. External Surfaces for: a.

Nicks

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal

Any number, 0.016 in. (0.40 mm)

Blend to remove damage

b.

Dents

Any number, 0.016 in. (0.40 mm) deep

Not repairable

Replace HPT rotor per WP 201 00

c.

Scratches

Any number, any length, 0.005 in. (0.12 mm) deep, after removal of high metal

Any number, 0.010 in. (0.26 mm) deep

Blend to remove damage

Not serviceable

Any number that can be removed by blending to max of 0.031 in. (0.78 mm) deep. Holes can be increased in diameter by 0.125 in. (3.17 mm) and edge radius increased to 0.125 in. (3.17 mm) max (true radius not required) to remove damage

Blend to remove damage

5. Cooling Air Holes for: a.

Nicks and scratches

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

STAGES 1 AND 2 BLADE RETAINERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace blade retainer per WP 202 00. However, engine vibration levels may not be exceeded during engine operation

b.

Nicks and dents

Any number, 0.010 in. (0.25 mm) deep

Any number, 0.016 in. (0.41 mm) deep

Blend to remove damage

c.

Scratches

Any number, any length, 0.010 in. (0.25 mm) deep

Any number, 0.016 in. (0.40 mm) deep

Blend to remove damage

Not repairable

Replace HPT rotor per WP 201 00

STAGES 1 AND 2 DISKS 1. All Areas for: a.

Cracks

Not serviceable

2. Dovetail Serrations for: a.

Nicks and dents

Three dovetail serrations, 0.010 in. (0.25 mm) deep, after removal of high metal

Corner radii of dovetail and posts can be locally increased to 0.078 in. (1.98 mm) radius to remove nicks and dents

Blend to remove damage

b.

Scratches

Any number, any length, 0.003 in. (0.07 mm) deep, after removal of high metal, if located on root radii or pressure faces. Root radii or pressure face scratches are not serviceable

Not repairable

Replace HPT rotor per WP 201 00

c.

Fretting

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00 7

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Rim (OD of disks) for: a.

Nicks

Any number, 0.016 in. (0.40 mm) deep, after removal of high metal

Any number that can be removed by blending to max depth of 0.047 in. (1.19 mm)

Blend to remove damage

b.

Dents

Any number, 0.047 in. (1.19 mm) deep, after removal of high metal

Not repairable

Replace HPT rotor per WP 201 00

c.

Scratches

Any number, 0.016 in. (0.40 mm) deep, after removal of high metal

Any number that can be removed by blending to max depth of 0.047 in. (1.19 mm) and 0.25 in. (6.3 mm) long

Blend to remove damage

d.

Galling

Any number, 0.010 in. (0.25 mm) deep, 0.50 in. (12.7 mm) long, after removal of high metal and sharp edges

Not repairable

Replace HPT rotor per WP 201 00

4. Disk Web (Stage 2 Disk Only) for: a.

Nicks and scratches

Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal

Any number that can be removed by blending to max depth of 0.031 in. (0.78 mm) and 0.50 in. (12.7 mm) long. Polish to same finish as adjacent area

Blend to remove damage

b.

Dents

Any number, 0.063 in. (1.60 mm) deep

Not repairable

Replace HPT rotor per WP 201 00

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

STAGES 1 AND 2 DAMPERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace damper

b.

Galling

0.005 in. (0.12 mm) deep, after removal of high metal

Not repairable

Replace damper

STAGES 1 AND 2 SEALS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace seal

b.

Galling

0.005 in. (0.12 mm) deep, after removal of high metal

Not repairable

Replace seal

0.020 in. (0.50 mm) deep, after removal of high metal

Not repairable

Replace seal

2. End Faces for: a.

Nicks, dents, and scratches

THERMAL SHIELD 1. All Areas Except Seal Serrations for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

b.

Scratches

Any number, any length, 0.005 in. (0.12 mm) deep, 0.50 in. (12.7 mm) long

Any number, 0.010 in. (0.26 mm) deep

Blend to remove damage

c.

Nicks

Any number, any length, 0.010 in. (0.25 mm) deep

Any number, 0.016 in. (0.41 mm) deep

Remove high metal

d.

Dents

Any number, 0.031 in. (0.78 mm) deep

Not repairable

Replace HPT rotor per WP 201 00

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. External Seal Serrations for: a.

Turned metal

Not serviceable

Any amount

Remove high metal

NOTE

•

Maximum cumulative blend length of any one tooth shall not exceed 5 in. (127 mm).

•

Total cumulative length of all blends on three serrations shall not exceed 10 in. (254 mm).

•

Measurements to be made at OD of serrations (including blend radius).

•

Do not leave sections of seal tooth shorter than 1.0 in. (25.4 mm) long between blends.

b.

Cracked or cracked out serrations

Not serviceable

Any number may be blended out if completely removed within limits of preceding NOTE and Blend min OD limits of figure 2

Blend and inspect for cracks

c.

Nicks

Any number, 0.031 in. (0.78 mm) deep, if there is no crack and high metal is removed

Any number may be blended out if completely removed within limits of preceding NOTE and figure 2

Blend and inspect for cracks

d.

Dents

Any number, 0.031 in. (0.78 mm) deep

Any number may be blended out if completely removed within limits of preceding NOTE and figure 2

Blend and inspect for cracks

e.

Bending

Not serviceable

Any number may be straightened at max 0.125 in. (3.17 mm) axially

Straighten; may not be overbent and rebent. Inspect straightened area for cracks

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

AFT SHAFT 1. All Areas Except Seal Serrations for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

Accept nicks and dents 0.063 in. (1.60 mm) deep, after removal of high metal

Total removal of half of entrance thread is permissible if remainder of threads are free of damage. If entrance thread is free of damage, cumulative length of damage in other areas shall not exceed 50 percent of one complete thread

Remove all threads, pickup, and high metal

2. Threads for: a.

Damage (nicks, dents, pickup, or high metal)

3. No. 5 Bearing Journal for: a.

Pickup or high metal

Not serviceable

Any amount

Remove high metal

b.

Nicks, dents, scores, and scratches

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal, if not more than 5 percent of journal OD affected in any 90 degree sector

Not repairable

Replace HPT rotor per WP 201 00

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. No. 5 Bearing Air and Oil Seal Serrations for: NOTE

• Total cumulative length of all blends on aft shaft forward rotating air seal serrations shall not exceed 7 in. (177.8 mm).

•

Total cumulative length of all blends on aft shaft aft rotating air seal serrations and air/oil seal serrations shall not exceed 3 in. (76.2 mm).

•

Measurements to be made at OD of serrations (including blend radius).

• Minimum blend radius to be 0.063 in. (1.60 mm). Do not leave serration sections less than 0.50 in. (12.7 mm) long between blends.

a.

Cracked or cracked out serrations

Not serviceable

Any number may be blended out if completely removed by blending max of 0.100 in. (2.5 mm) deep, 1.0 in. (25.4 mm) long and within limits of preceding NOTE and figure 2

Blend and inspect for cracks

b.

Nicks and dents

Any number, 0.031 in. (0.78 mm) deep, if there is no crack and high metal is removed

Any number may be blended out if completely removed by blending max of 0.100 in. (2.5 mm) deep, 1.0 in. (25.4 mm) long, and within limits of preceding NOTE and figure 2

Blend and inspect for cracks

c.

Bending

Not serviceable

Any number may be straightened at max 0.063 in. (1.60 mm) axially

Straighten with hand tools. Serration shall not be overbent and rebent. Inspect straightened area for cracks

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Flanges for: a.

Nicks

Any number, 0.016 in. (0.40 mm) deep

Any number that can be removed by blending max of 0.031 in. (0.78 mm) deep

Blend to remove damage

b.

Dents

Any number, 0.031 in. (0.78 mm) deep

Not repairable

Replace HPT rotor per WP 201 00

c.

Scratches

Any number, any length, 0.010 in. (0.25 mm) deep, after removal of high metal

Any number that can be removed by blending max of 0.016 in. (0.40 mm) deep

Blend to remove damage

d.

High metal

Not serviceable

Any amount

Remove high metal

e.

Damaged wrenching slots

0.031 in. (0.78 mm) deformation, after removal of high metal

Not repairable

Replace HPT rotor per WP 201 00

6. All Other Areas for: a.

Nicks

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal

Any number that can be removed by blending max of 0.016 in. (0.40 mm) deep

Blend to remove damage

b.

Dents

Any number, 0.016 in. (0.40 mm) deep

Not repairable

Replace HPT rotor per WP 201 00

c.

Scratches

Any number, any length, 0.005 in. (0.12 mm) deep

Any number that can be removed by blending max of 0.010 in. (0.25 mm) deep

Blend to remove damage

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

HPT ROTOR DAMPER SLEEVE 1. All Areas for: a.

Nicks and scratches

Not serviceable

Any amount to 0.050 in. (1.27 mm) deep

Remove high metal

b.

Buckling

Not serviceable

Not repairable

Replace HPT rotor damper sleeve*

c.

Cracks

Not serviceable

Not repairable

Replace HPT rotor damper sleeve*

Any amount to 0.030 in. (0.76 mm) deep. No fretting permitted in fillet at aft area J

Any amount to 0.006 in. (0.15 mm) deep

Remove high metal

2. Area J for: a.

Fretting

PRESSURE TUBE 1. Internal Surfaces for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

b.

Buckling

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

COUPLING NUT 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace coupling nut

b.

Pickup or high metal

Not serviceable

Not repairable

Replace coupling nut

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of other thread damage shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to unnecessarily remove protective finish. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Missing silver plating

Five percent missing

Not repairable

Replace part

c.

Pickup and high metal

Not serviceable

Any amount

Remove pickup and high metal

Not serviceable

Any amount

Remove pickup and high metal

3. Contact Face for: a.

Pickup and high metal

4. Splines for: a.

Nicks and dents

Any amount, 0.010 in. (0.25 mm) deep by 0.030 in. (0.76 mm) wide by 0.125 in. (3.17 mm) long

0.030 in. (0.76 mm) deep by 0.063 in. (1.60 mm) wide by 0.50 in. (12.70 mm) long over 85 percent of all tooth surfaces *May be repairable. Consult GE for disposition of replaced parts.

Remove high metal and blend sharp edges

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. HPT Rotor 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 426 00

Figure 2. Blend Repair of Seal Serrations

Figure 3. HPT Rotor Damper Sleeve 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 4. HPT Pressure Tube Table 2. HPT Rotor Blade Inspection On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

STAGE 1 BLADES 1. Leading Edge for: a.

Axial and radial cracks in area A only

Any number, not extending beyond leading edge or connect to adjacent nose holes

Not repairable

Replace blade per WP 202 00

b.

Cracks not intersecting cooling holes in area B

Not serviceable

Not repairable

Replace blade per WP 202 00

c.

Radial cracks out of leading edge holes in area B

Any number, if not connecting 2 holes and do not turn into axial direction

Not repairable

Replace blade per WP 202 00

18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Leading Edge for: - (cont.) d.

Axial cracks out of leading edge holes in area B

Not serviceable

Not repairable

Replace blade per WP 202 00

e.

Nicks and scratches in area A

Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal or nicks do not extend into or block nose or gill holes

Not repairable

Replace blade per WP 202 00

f.

Nicks and scratches in area B

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in nick or scratch itself

Not repairable

Replace blade per WP 202 00

g.

Dents in area A

Any number, if damage does not cause torn metal or cracks beyond gill holes

Not repairable

Replace blade per WP 202 00

19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Leading Edge for: - (cont.) h.

Dents in area B

Three dents, 0.010 in. (0.25 mm) deep or out of contour 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion, except that surface distortion is allowed in dent itself

Not repairable

Replace blade per WP 202 00

i.

Tears

Not serviceable

Not repairable

Replace blade per WP 202 00

j.

Blocked leading edge holes

Total of three holes, one only in area B, separated by one open hole

Not repairable

Replace blade per WP 202 00

k.

Missing metal in area A or B

Not serviceable

Not repairable

Replace blade per WP 202 00

l.

Missing coating

No parent material exposed

Not repairable

Replace blade per WP 202 00

2. Trailing Edge for: a.

Cracks

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Blocked air holes

Three holes in any area above seventh hole, if not adjacent to each other. None allowed in bottom seven holes

Not repairable

Replace blade per WP 202 00

c.

Oxidation/ erosion

Degradation of edge thickness to 0.05 in. (1.2 mm), if trailing edge hole wall each side is no less than 0.015 in. (0.38 mm)

Not repairable

Replace blade per WP 202 00

20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Trailing Edge for: - (cont.) d.

Nicks and scratches in area A

Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, and 0.125 in. (3.17 mm) apart

Not repairable

Replace blade per WP 202 00

e.

Nicks and scratches in area B

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long and 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion, except that surface distortion is allowed in nick or scratch itself

Not repairable

Replace blade per WP 202 00

f.

Dents in area A

Six allowed, 0.010 in. (0.25 mm) deep or out of contour

Not repairable

Replace blade per WP 202 00

g.

Dents in area B

Three dents, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion except that surface distortion is allowed in dent itself

Not repairable

Replace blade per WP 202 00

h.

Tears

Not serviceable

Not repairable

Replace blade per WP 202 00

21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Concave and Convex Surfaces for: a.

Cracks in intersecting cooling holes

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Axial cracks out of gill holes

Not serviceable

Not repairable

Replace blade per WP 202 00

c.

Blocked gill holes (1)

Concave side gill holes

Two holes if not adjacent to each other

Not repairable

Replace blade per WP 202 00

(2)

Convex side gill holes

Three holes only. One within first seven holes from root. Each plugged hole must be separated from next plugged hole by two open holes, except above tenth hole from root where two adjacent holes may be plugged, if third plugged hole (if there is one) is three or more holes from plugged adjacent holes

Not repairable

Replace blade per WP 202 00

22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Concave and Convex Surfaces for: - (cont.) d.

Nicks and scratches in area A

Any number, 0.015 in. (0.38 mm) deep and no restrictions on length or spacing; any number, 0.25 in. (6.3 mm) deep, 0.100 in. (2.5 mm) long and 0.250 in. (6.35 mm) apart

Not repairable

Replace blade per WP 202 00

e.

Nicks and scratches in area B

Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart

Not repairable

Replace blade per WP 202 00

f.

Dents in area A

Any number, 0.030 in. (0.76 mm) deep, 0.100 in. (2.54 mm) diameter

Not repairable

Replace blade per WP 202 00

g.

Dents in area B not allowed in fillet radius at leading and trailing edges

Any number, 0.015 in. (0.38 mm) deep separated from any other dents by 0.100 in. (2.54 mm)

Not repairable

Replace blade per WP 202 00

4. Tip Area for: a.

Nicks and scratches

Any number

Blend to remove damage

23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Tip Area for: - (cont.) b.

Radial cracks in parent metal

Three radial cracks, 0.200 in. (5.08 mm) long each extending inward from top of blade. Any number that extend from top of blade to top of tip cap retention lug. If cracks extend into tip cap, use limits for cracks in tip cap

Not repairable

Replace blade per WP 202 00

c.

Axial cracks in parent metal

One per side, 0.400 in. (10.16 mm) long, if damage is above tip cap retention lug

Not repairable

Replace blade per WP 202 00

d.

Dent or curled

Any amount, if damage is above tip cap retention lug and no cracked parent metal is visible below tip cap lug

Not repairable

Replace blade per WP 202 00

e.

Wear due to shroud rub

Wear may not extend to within 0.070 in. (1.77 mm) of tip cap retention lug

Not repairable

Replace blade per WP 202 00

f.

Missing metal

Any amount above tip cap retention lug

Not repairable

Replace blade per WP 202 00

24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Tip Area for: - (cont.) g.

Missing coating

Any amount

_

_

5. Tip Cap for: a.

Blocked air holes

One hole per cap can be plugged

Not repairable

Replace blade per WP 202 00

b.

Braze area or cracks in length of braze

Any number, if cumulative length does not exceed 0.200 in. (5.08 mm) and braze seal is maintained

Not repairable

Replace blade per WP 202 00

c.

Cracks

One allowed in cap in each flat 0.100 in. (2.54 mm) long. Any cap crack connecting two or more cooling holes is not allowed. Any crack accompanied by cap bowing is not allowed

Not repairable

Replace blade per WP 202 00

6. Top Surface and Edges of Blades Platform (not including root radius) for: a.

Nicks and scratches

Any number, 0.030 in. (0.76 mm) deep

Not repairable

Replace blade per WP 202 00

b.

Dents

Any number, 0.030 in. (0.76 mm) deep

Not repairable

Replace blade per WP 202 00

c.

Cracks ( forward and aft edges only)

Any number, any length, if no cracks extend completely through plat form thickness or into root radius of airfoil

Not repairable

Replace blade per WP 202 00

25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

7. Airfoil for: a.

Metal splatter

Any amount, if thickness does not exceed 0.005 in. (0.12 mm). Chipping or flaking is acceptable

Not repairable

Replace blade per WP 202 00

b.

Distortion or evidence of burning or melting

Not serviceable

Not repairable

Replace blade per WP 202 00

8. Forward Seal Lip for: a.

Circumferential wear groove on OD and ID of forward seal lip

Groove may be 0.02 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from for ward edge of seal lip

Not repairable

Replace blade per WP 202 00

b.

Circumferential wear groove on OD of aft seal

Groove may be 0.02 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from aft edge of seal lip

Not repairable

Replace blade per WP 202 00

STAGE 2 BLADES ONLY 1. Leading and Trailing Edges for: a.

Cracks

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Nicks and scratches in area A

Any number

Not repairable

Replace blade per WP 202 00

26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Leading and Trailing Edges for: - (cont.) c.

Nicks and scratches in area B (including root radius)

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion, except that surface distortion is allowed in nick or scratches itself

Not repairable

Replace blade per WP 202 00

d.

Dents in area A

Any number, 0.010 in. (0.25 mm) deep or out of contour, 0.050 in. (1.27 mm) apart

Not repairable

Replace blade per WP 202 00

e.

Dents in area B (including root radius)

Any number, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in dent itself

Not repairable

Replace blade per WP 202 00

f.

Tears

Not serviceable

Not repairable

Replace blade per WP 202 00

g.

Missing coating

No parent material exposed

Not repairable

Replace blade per WP 202 00

27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Concave and Convex Surfaces for: a.

Cracks

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Nicks and scratches in area A

Any number, 0.008 in. (0.20 mm) deep and no restrictions on length or spacing, or any number 0.020 in. (0.50 mm) deep, 0.060 in. (1.52 mm) long, and 0.250 in. (6.35 mm) apart

Not repairable

Replace blade per WP 202 00

c.

Nicks and scratches in area B (including root radius)

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart if there is no torn metal, raised metal or surface distortion, except that surface distortion is allowed in nick or scratch itself

Not repairable

Replace blade per WP 202 00

d.

Dents in area A

Any number, 0.030 in. (0.76 mm) deep, 0.060 in. (1.52 mm) diameter

Not repairable

Replace blade per WP 202 00

28 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Concave and Convex Surfaces for: - (cont.) e.

Dents in area B (including root radius)

Any number, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in dent itself

Not repairable

Replace blade per WP 202 00

3. Tip Area for: a.

Nicks and scratches

Any number

_

Blend to remove damage

b.

Radial cracks in parent metal

Three radial cracks 0.200 in. (5.08 mm) long each extending inward from top of blade. Any number that extend from top of blade to top of tip cap lip. If cracks extend into tip cap, use limits for cracks in tip cap

Not repairable

Replace blade per WP 202 00

c.

Axial cracks in parent metal

One per side, 0.400 in. (10.16 mm) long, if damage is above tip cap lip

Not repairable

Replace blade per WP 202 00

d.

Bent or curled

Any amount, if damage is above tip cap lip and no cracked parent metal is visible below tip cap lip

Not repairable

Replace blade per WP 202 00

29 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Tip Area for: - (cont.) e.

Wear due to shroud rub

Wear may not extend to within 0.070 in. (1.77 mm) of tip cap lip

Not repairable

Replace blade per WP 202 00

f.

Missing metal

Any amount above tip cap lip

Not repairable

Replace blade per WP 202 00

g.

Missing coating

Any amount

_

_

4. Tip Cap for: a.

Blocked air holes

No holes may be plugged

Not repairable

Replace blade per WP 202 00

b.

Braze area or cracks in length of braze

No cracks allowed

Not repairable

Replace blade per WP 202 00

c.

Cracks in tip cap

Any number which do not extend more than 0.010 in. (0.25 mm) across tip cap flat. Cracks accompanied by cap bowing not allowed

Not repairable

Replace blade per WP 202 00

5. Top Surface and Edges of Platform (not including root radius) for: a.

Cracks on side of platform or forward and aft edges

Any number, any length, if no cracks extend into root radius of airfoil

Not repairable

Replace blade per WP 202 00

b.

Nicks and scratches

Any number, 0.030 in. (0.76 mm) deep

Not repairable

Replace blade per WP 202 00

c.

Dents

Any number, 0.030 in. (0.76 mm) deep

Not repairable

Replace blade per WP 202 00

30 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

6. Blade Shank for: a.

Nicks and scratches

Any number, 0.010 in. (0.25 mm) deep

Not repairable

Replace blade per WP 202 00

b.

Dents

Three per surface 0.030 in. (0.76 mm) deep

Not repairable

Replace blade per WP 202 00

c.

Cracks

Not serviceable

Not repairable

Replace blade per WP 202 00

d.

Indications of cracks in shank between dovetail and damper boss areas

Not serviceable

Not repairable

Replace blade per WP 202 00

7. Dovetail Serrations for: a.

High Metal

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Nicks, dents, and scratches in areas D and E

Not serviceable

Six per serration 0.060 in. (1.52 mm) in diameter, 0.005 in. (0.12 mm) deep, separated by 0.125 in. (3.17 mm), after removal of high metal

Hand stone

c.

Nicks, dents, and scratches in pressure face and area F

Not serviceable

Not repairable

Replace blade per WP 202 00

8. Damper Boss Area for: a.

Cracks

Not serviceable

Not repairable

Replace blade per WP 202 00

b.

Fretting or galling

0.005 in. (0.12 mm) deep

Not repairable

Replace blade per WP 202 00

31 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

9. Aft Seal Lips for: a.

Cracks

b.

Circumferential wear groove on OD of aft seal lip

Not serviceable

Not repairable

Groove may be Not repairable 0.020 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from aft edge of seal lip *May be repairable. Consult GE for disposition of replaced part.

Replace blade per WP 202 00 Replace blade per WP 202 00

32 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 426 00

Figure 5. HPT Stage 1 Rotor Blade 33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 426 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 6. HPT Stage 2 Rotor Blade 34 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 426 00

Figure 7. Dovetail Serrations

35/(36 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 1 NOZZLE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 28 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 28 ................. 0 Alphabetical Index Subject

Page

High Pressure Turbine Stage 1 Nozzle Disassembly. ....................................................... 20 High Pressure Turbine Stage 1 Nozzle Inspection............................................................ 3 High Pressure Turbine Stage 1 Nozzle Open Area (A4) Inspection. ................................ 24 High Pressure Turbine Stage 1 Nozzle Reassembly. ........................................................ 21

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection and repair of LM2500+ Models GK and GV gas generators and Models PK and PV gas turbine high pressure turbine (HPT) stage 1 nozzle assembly.

2.

3.

4.

5.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I Preventive Maintenance

GEK 105054 Chapter 11

Support Equipment. Nomenclature

Part No.

Gage, High Pressure Turbine Nozzle Open Area

2C6505

Consumable Material. Nomenclature

Part No./Specification

Thread Lubricant

GE Spec A50TF201

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Turbine Stage 1 Nozzle Inspection. a.

Inspect HPT stage 1 nozzle per table 1 and figures 1 and 2. Table 1. HPT Stage 1 Nozzle Inspection On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

COMPRESSOR REAR FRAME (CRF) SEAL SUPPORT 1. Cone body for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.

Dents

Three dents, 0.30 (7.6 mm) in. diameter, 0.06 in. (1.5 mm) deep. Do not remove high metal

Not repairable

Replace part*

c.

Nicks and scratches

Any number, 0.005 in. (0.12 mm) deep, after removal of high metal

Not repairable

Replace part*

2. Mounting Flange for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.

Nicks, dents, or scratches

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal if not across full radial surface of flange

Not repairable

Replace part*

Six radial cracks, any length, minimum separation of 2.00 in. (50.8 mm). Circumferential cracks not serviceable

Not repairable

Replace part*

3. Stiffener for: a.

Cracks

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Stiffener for: - (cont.) b.

Dents

Three dents, 0.50 in. (12.7 mm) diameter, 0.06 in. (1.5 mm) deep. Do not remove high metal

Any amount

Mechanically straighten. Inspect for cracks

4. Self-Locking Nut Gang Channel for: a.

Improperly positioned or missing nuts

Not serviceable

Any number

Reposition or replace nut*

b.

Bent channel legs

Not serviceable

Any amount that will not produce cracking or improper nut containment

Straighten. Inspect for cracks

c.

Loss of running torque on nuts

Not serviceable

Not repairable

Replace part*

Any amount

Replace pin*

Not repairable

Replace cover*

5. Locating Pin (located on Rear Flange) for: a.

Loose or missing pins

Not serviceable

CRF SEAL SUPPORT BOLT COVER 1. All Areas of Cover for: a.

Cracks

Not serviceable

INNER AND OUTER HPT STAGE 1 NOZZLE SEALS 1. Seal Ring and Lugs for: a.

Cracks

Not serviceable

b.

Warpage

Not serviceable

Any amount

Mechanically straighten; no cracks allowed after rework

c.

Burned or missing lugs

Any amount, 0.100 in. (2.54 mm) deep

Not repairable

Replace part*

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Rivets for: a.

Looseness

Not serviceable

Not repairable

Replace rivet*

b.

Tack weld broken

Not serviceable

Not repairable

Replace part*

Any amount, 0.010 in. (0.25 mm) deep

Not repairable

Replace part*

3. Seal Lips for: a.

Wear or galling

BAFFLE LINER 1. All Seal Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.

Bent or distorted

Any amount, if proper assembly can be accomplished and required minimum clearance can be maintained

Any amount

Mechanically straighten until part will assemble and minimum clearance requirements can be maintained. Inspect for cracks

c.

Bolts-air baffle to nozzle support for tightness

No loose bolts allowed

Any number

Tighten to specified torque

2. Support for: a.

Cracks

Any number, radial 0.25 in. (6.3 mm) hole

Not repairable

Replace part*

b.

Bends and/or distortion

Any amount, if proper assembly can be accomplished and required clearances maintained

_

Mechanically straighten until part will assemble and minimum clearances can be maintained. Inspect for cracks

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

NOTE

• The nozzle vane segment limits have been defined assuming that a

hot section overhaul will be performed in an additional 15,000 or less hours of operation and that the engine will be borescoped per the semi-annual inspection requirements in Volume 1, Chapter 11.

•

A maximum of six HPT stage 1 nozzle segments may be replaced without remeasuring the HPT stage 1 nozzle assembly open area (A4).

HPT STAGE 1 NOZZLE SEGMENT 1. Vane Airfoil for: a.

Cracks propagating from nose holes toward other nose holes, including those interconnecting holes

Any number, any length, maximum width of 0.005 in. (0.12 mm), and three cracks maximum width of 0.010 in. (0.25 mm) are acceptable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

NOTE To assist in visually gauging observed defects by comparison, the center-to-center dimension between nose or gill holes in any given row (radial direction) is approximately 0.094 in. (2.38 mm). b.

Cracks propagating aft from last row of nose holes on concave or convex side per airfoil

Any number, 0.005 in. (0.12 mm) wide and 0.150 in. (3.81 mm) long. One crack, 0.010 in. (0.25 mm) wide, between nose and gill holes on one side if same crack does not continue on other side. See Note

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Vane Airfoil for: - (cont.) NOTE Cracks from nose holes toward gill holes shall be more than 0.15 in. (3.8 mm) from cracks between flange cooling hole and gill hole. c.

Cracks propagating from concave and convex gill holes

Any number, 0.080 in. (2.03 mm) long One crack per side connecting up to three gill holes allowed. One crack permitted to connect with forward inner or outer flange cooling hole

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

d.

Axial cracks in concave surface

Three cracks not to exceed cumulative length of 1.00 in. (25.4 mm) per airfoil

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

e.

Radial cracks in concave surface

One crack, 0.50 in. (12.7 mm) long per airfoil, if it does not intersect with an axial crack. No radial cracks allowed within 0.50 in. (12.7 mm) from trailing edge

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Vane Airfoil for: - (cont.) f.

Cracks in concave side originating in trailing edge cooling slots and ribs

Any number of cracks, 0.120 in. (3.04 mm) long, extending from trailing edge slots. Each slot rib may have one crack extend across full width of rib, but not through vane

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

g.

Cracks on convex surface (not emanating from trailing edge)

Three cracks not to exceed cumulative length of 0.50 in. (12.7 mm). No radial cracks allowed in an area 1.20-1.40 in. (30.435.5 mm) from trailing edge, except cracks in airfoil to platform radius are acceptable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

h.

Cracks from trailing edge forward (convex surface)

Any number, 0.120 in. (3.04 mm) long. Two per vane up to 0.35 in. (8.8 mm) long

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Vane Airfoil for: - (cont.) i.

Burns in trailing edge (loss of metal)

One area per vane, 0.75 in. (19.0 mm) long radially, 0.375 in. (9.52 mm) long axially

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

j.

Burns on concave or convex side

One area per vane, 0.75 in. (19.0 mm) long radially, 0.375 in. (9.52 mm) long axially

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

k.

Burns or erosion on vane leading edge

One area per vane, 0.625 in. (15.8 mm) wide, 0.75 in. (19.0 mm) long radially. No burn through allowed

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

l.

Nicks, scores, scratches, dents, or pits

Any number, any length, 0.010 in. (0.25 mm) deep. Three per airfoil, 0.020 in. (0.50 mm) deep, 0.10 in. (2.5 mm) long. Two nicks or dents, 0.05 in. (1.2 mm) deep within 0.75 in. (19.0 mm) of trailing edge

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Vane Airfoil for: - (cont.) NOTE The trailing edge slots shall be able to accept a 0.020 in. (0.50 mm) diameter pin. All sharp gouges at trailing edge should be removed by blending. m.

Tears, gouges, and nicks (loss of metal) on airfoil trailing edge (aft 0.40 in. (10.1 mm) of vane airfoil)

Three per airfoil, 0.06 in. (1.5 mm) long axially and 0.12 in. (3.0 mm) long radially. One per airfoil, 0.20 in. (5.0 mm) long axially and 0.30 in. (7.6 mm) long radially, after removal of high metal

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

n.

Bulging, bowing, or creases

Trailing edge bowing on aft 0.40 in. (10.1 mm) of airfoil is not to exceed 0.06 in. (1.5 mm) from original contour. Bulging of convex surface and concave side creases are acceptable, if no cracks on crease or bulge are present

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

o.

Blocked nose and gill air holes

Six nose holes, five convex surface gill holes, and eight concave surface gill holes. Any two adjacent holes may be blocked if adjacent two holes are open

Any number

Mechanically open holes

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Vane Airfoil for: - (cont.) p.

Blocked trailing edge air slots

Holes adjacent to each platform may be partially blocked, if they will accept a 0.025 in. (0.63 mm) pin

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

q.

Missing coating

Any amount, if burn and corrosion limits are met

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

NOTE Craze cracking is defined as numerous superficial surface cracks which have no measurable width or depth. r.

Craze cracking

Any amount

_

_

2. Outer Platform for: a.

Cracks in welds between vanes

0.63 in. (16.0 mm) length of weld

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

b.

Cracks in parent metal (excluding flanges and welds)

Any number, 0.85 in. (21.5 mm) long. See Note. One interconnecting crack between platform cooling holes is allowed. Cumulative length of all parent metal cracks including cracks in airfoil-toplatform fillet (step o.) is not to exceed 2.00 in. (50.8 mm)

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Outer Platform for: - (cont.) c.

Circumferential cracks on forward flange seal and trailing edge flange

Not serviceable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

d.

Radial cracks on forward flange seal and trailing edge flange

One crack on forward flange, 0.25 in. (6.3 mm) long, one crack on trailing edge flange, 0.25 in. (6.3 mm) long, and any number, 0.100 in. (2.54 mm) long

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

e.

Radial cracks, propagating from outer flange cooling holes

Any number, max. 0.25 in. (6.3 mm) long. One crack, 0.40 in. (10.1 mm) long radially outward and one crack 0.40 in. (10.1 mm) long radially inward; one crack permitted to connect any cooling hole

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

f.

Nicks, scores, scratches, and dents on platform surfaces

Any number, 0.030 in. (0.76 mm) deep, after removal of high metal

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Outer Platform for: - (cont.) g.

Wear, rub marks, or galling of forward flange seal and trailing edge flange

h.

Burns or erosion (1)

Corrosion, erosion, and burns on vane platform

Any amount, 0.010 in. (0.25 mm) deep, after removal of high metal. Also, two wear areas may exist on forward flange faces, 0.60 in. (15.2 mm) long by 0.25 in. (6.3 mm) wide where thickness may be 0.036 in. (0.91 mm)

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

Any number. Burn through allowed. Loss of metal not to exceed 0.13 in. (3.3 mm) wide by 0.50 in. (12.7 mm) long

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

NOTE On borescope vane, erosion up to 0.13 in. (3.3 mm) on inside of borescope hole is acceptable. (2)

i.

Borescope hole

Any amount, 0.13 in. (3.3 mm) deep

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

Cracks in insert-to-vane tack weld

One weld may be cracked at each insert

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Outer Platform for: - (cont.) j.

Plugged air holes (deposits)

Three per segment except in outer band leading edge where only one is allowed

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

k.

Erosion or missing material on aft flange seal

Any amount not exceeding 20 percent of circumferential length

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

l.

Cracks in aft flange seal lip

Axial cracks, any number, any length, 0.010 in. (0.25 mm) wide. Two circumferential cracks, 0.15 in. long (3.8 mm) are acceptable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

Cracks in insert flange

Two per insert

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

n.

Seal slot breakthrough

Seal slot breakthrough is permitted only on aft side on trailing vane side surface

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

o.

Cracks in airfoil-toplatform fillet

Any number, 0.25 in. (6.3 mm) long. Cumulative length of all airfoil-toplatform fillet cracks and parent metal cracks (step b.) is not to exceed 2.00 in. (50.8 mm)

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

m.

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Outer Platform for: - (cont.) NOTE Scarfing is defined as grooves formed during manufacturing or repair, which are located adjacent to, and in-line with the cooling holes. p.

Scarfing on aft flange seal lip

Ten places, not more than 0.025 in. (0.63 mm) deep. One may have any amount, if no break through on gas flow side

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

q.

Missing coating

Any amount, if burn and erosion limits are met

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

NOTE Craze cracking is defined as numerous superficial surface cracks which have no measurable width or depth. r.

Craze cracking

Any amount

_

_

3. Inner Platform for: a.

Cracks between vane in weld

One half length of weld

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

b.

Cracks in parent metal (excluding flanges and welds)

Any number, 0.85 in. (21.5 mm) long. See Note. One inter connecting crack between platform cooling holes is allowed

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Inner Platform for: - (cont.) NOTE Cumulative length of all inner platform cracks, including cracks in airfoil-to-fillet area, is not to exceed 2.00 in. (50.8 mm). c.

Circumferential cracks on forward flanges

Not serviceable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

d.

Radial cracks on forward seal

One crack, 0.25 in. (6.3 mm)

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

e.

Cracks on mounting flange except in weld between vanes

One crack, 0.25 in. (6.3 mm) long not emanating from or to mounting hole

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

f.

Nicks, scores, scratches, and dents on platform surfaces and flanges

Any number, 0.03 in. (0.76 mm) deep

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

g.

Wear, rub marks, or galling on forward flanges

Any amount, 0.010 in. (0.25 mm.) deep, after removal of high metal. Also, two wear areas may exist on forward flange, 0.60 in. (15.2 mm) long by 0.25 in. (6.3 mm) wide where thickness may be 0.036 in. (0.91 mm)

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Inner Platform for: - (cont.) h.

Plugged air holes (deposits)

Three per segment except in outer band leading edge where only one is allowed

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

i.

Corrosion, erosion, and burn on inner platform

Any amount. Burn through allowed. Loss of metal not to exceed 1.00 in. (25.4 mm) long by 0.25 in. (6.3 mm) wide

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

j.

Seal slot breakthrough

Permitted only on forward side of aft most slot and aft side of forward slot

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

k.

Missing coating

Any amount, if burn and erosion limits are met

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

l.

Metal voids (crack-like indications) in mounting flange on forward edge

Void in area A not to extend to hole. Voids in areas A, B, or C not to extend through flange

Not repairable

Replace nozzle segments

4. All areas for: a.

Metal splatter

Not serviceable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

b.

Discoloration

Any amount

_

_

* May be repairable. Consult GE for disposition of replaced parts.

17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. HPT Stage 1 Nozzle Assembly 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 427 00

Figure 2. HPT Stage 1 Nozzle Vanes 19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00 7.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

High Pressure Turbine Stage 1 Nozzle Disassembly. a.

Place HPT stage 1 nozzle forward end down on working surface.

b.

Using marking pen, position mark HPT stage 1 nozzle segment vane with trailing edge closest in-line with 12:00 o’clock position as vane 1. NOTE Ensure single HPT stage 1 nozzle segment contains both vane 1 and vane 64.

c.

Indexing clockwise, aft looking forward (ALF), position mark remainder of HPT stage 1 nozzle segments.

d.

Using marking pen, matchmark forward windage cover segment (5, figure 1), baffle segments (3), inner and outer HPT stage 1 nozzle seals (7 and 8), and HPT stage 1 nozzle support (6) to HPT stage 1 nozzle assembly.

e.

Remove 18 shear bolts (4) that secure forward windage cover segment (5) and baffle segments (3) to HPT stage 1 nozzle support (6).

f.

Remove 18 baffle segments (3) and forward windage cover segment (5) from HPT stage 1 nozzle support (6). NOTE Ensure HPT stage 1 nozzle segments are properly supported during removal of HPT stage 1 nozzle support.

g.

Remove 64 shear bolts (2) and self-locking nuts (9) that secure HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6).

h.

Remove HPT stage 1 nozzle support (6) and place the 32 HPT stage 1 nozzle segments (1) on a working surface. Remove HPT stage 1 nozzle support (6).

i.

Disassemble HPT stage 1 nozzle as follows: (1)

Pull outer HPT stage 1 nozzle seal (8) radially outward enough to release one HPT stage 1 nozzle segment (1) runner.

(2)

Push HPT stage 1 nozzle segment (1) located adjacent to HPT stage 1 nozzle segment released in step (1) in axial direction until inner and outer nozzle seals (10 and 11) release from HPT stage 1 nozzle segment.

(3)

Tilt HPT stage 1 nozzle segment (1) to clear outer HPT stage 1 nozzle seal (8).

20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

8.

(4)

Pull HPT stage 1 nozzle segment (1) radially outward from inner HPT stage 1 nozzle seal (7).

(5)

Repeat steps (1) through (4) to disassemble 31 remaining HPT stage 1 nozzle segments (1).

High Pressure Turbine Stage 1 Nozzle Reassembly. NOTE

•

HPT stage 1 nozzle is composed of 32 segments. Thirty one segments are the same, one segment contains a borescope port.

•

If same parts from paragraph 7. are being reassembled, use matchmarks and positions marks made during disassembly to aid in orientation during reassembly.

a.

Place inner HPT stage 1 nozzle seal (7, figure 1) on working surface, forward side down.

b.

Install runner of HPT stage 1 nozzle segment (1) containing borescope port into inner HPT stage 1 nozzle seal (7).

c.

Using pliers, tighten clips of inner HPT stage 1 nozzle seal (7) onto HPT stage 1 nozzle segment runner. NOTE Use petrolatum to aid in holding inner and outer nozzle seals in place during assembly.

d.

Install inner and outer nozzle seals (10 and 11) into counterclockwise end of HPT stage 1 nozzle segment (1).

e.

Place HPT stage 1 nozzle segment (1) into inner HPT stage 1 nozzle seal (7) about 0.250.50 in. (6.4-12.7 mm) counterclockwise from HPT stage 1 nozzle segment with borescope port.

f.

Move HPT stage 1 nozzle segment (1) clockwise to engage inner and outer nozzle seals (10 and 11). Ensure nozzle seals engage. NOTE Visually inspect inner and outer nozzle seals to ensure proper seating.

g.

Using soft mallet, gently tap HPT stage 1 nozzle segment (1) in clockwise direction until 0.031-0.063 in. (0.79-1.6 mm) gap between HPT stage 1 nozzle segments.

21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

h.

Repeat steps d. through g. until 31 HPT stage 1 nozzle segments have been installed.

i.

Install last HPT stage 1 nozzle segment (1) as follows:

j.

(1)

Install inner and outer nozzle seals (10 and 11) into counterclockwise end of HPT stage 1 nozzle segment (1).

(2)

Using soft mallet, gently tap HPT stage 1 nozzle segments (1), between which last HPT stage 1 segment will fit, away from gap in segments.

(3)

Using extreme care, gently insert last HPT stage 1 segment into inner HPT stage 1 nozzle seal (7).

Using soft mallet, gently tap all HPT stage 1 nozzle segments (1) to seat runners into inner HPT stage 1 nozzle seal (7). NOTE In free state, assembled HPT stage 1 nozzle segments and inner HPT stage 1 nozzle seal are not concentric.

k.

Temporarily secure outer circumference of HPT stage 1 nozzle assembly until HPT stage 1 nozzle support (6) can be installed.

l.

If required, position mark HPT stage 1 nozzle vane No. 1 as follows: (1)

Locate HPT stage 1 nozzle segment (1) with borescope vane.

(2)

Indexing counterclockwise, ALF, count 18 vanes from vane located at top of borescope port segment.

(3)

Using marking pen, position mark vane trailing edge as top centerline. NOTE

•

Each HPT stage 1 nozzle segment has two mounting tabs. All right, ALF, mounting tabs have sleeve installed.

•

HPT stage 1 nozzle segment with borescope port has sleeve installed in both left and right mounting tabs.

m. Place HPT stage 1 nozzle support (6), forward end down, inside assembled HPT stage 1 nozzle assembly.

22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines n.

Align TOP mark on HPT stage 1 nozzle support (6) with HPT stage 1 nozzle segment (1) vane trailing edge position marked as top centerline vane. NOTE With TOP mark on HPT stage 1 nozzle support and top centerline vane aligned, all holes in mounting tabs of HPT stage 1 nozzle segments shall be aligned. Sleeves in mounting tabs shall engage holes in HPT stage 1 nozzle support.

o.

Using thread lubricant, lightly coat threads of 64 shear bolts (2) and contact faces of 64 self-locking nuts (9).

p.

Using 64 shear bolts (2), boltheads aft, and self-locking nuts (9), secure 32 HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6). Tighten bolts finger-tight.

q.

While holding HPT stage 1 nozzle segments radially inward, tighten bolts to final torque of 110-120 lb in. (12.5-13.5 N⋅m) of torque.

r.

Install 18 baffle segments (3) onto aft side of HPT stage 1 nozzle support (6).

s.

Using thread lubricant, lightly coat threads of shear bolts (4).

t.

Using 18 shear bolts (4) and three forward windage cover segments (5), secure 32 HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6). Tighten bolts to 90-100 lb in. (10.2-11.3 N⋅m) of torque.

u.

Install outer HPT stage 1 nozzle seal as follows: (1)

Remove temporary restrain from outer circumference of HPT stage 1 nozzle assembly.

(2)

Place outer HPT stage 1 nozzle seal (8) on working surface, forward side down.

(3)

Place HPT stage 1 nozzle support (6) inside outer HPT stage 1 nozzle seal (8).

(4)

Raise and align outer HPT stage 1 nozzle seal (8) with runner on outside diameter of HPT stage 1 nozzle segment at 12:00 o’clock position.

(5)

Using soft mallet, gently tap outer HPT stage 1 nozzle seal (8) onto HPT stage 1 nozzle segment (1) until fully seated.

(6)

Indexing clockwise, ALF, seat outer HPT stage 1 nozzle seal (8) onto remaining 31 HPT stage 1 nozzle segments. Ensure outer HPT stage 1 nozzle seal is fully seated.

23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00 (7) 9.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Using soft mallet, gently tap outer HPT stage 1 nozzle seal (8), as required to center HPT stage 1 nozzle assembly.

High Pressure Turbine Stage 1 Nozzle Open Area (A4) Inspection. NOTE Measurement of the open area (A4) is only required if more than six HPT stage 1 nozzle segments are replaced.. a.

Prepare HPT nozzle open area gage, 2C6505, as follows: (1)

Pull lower finger lock (4, figure 3) to unlock lower finger (5) assembly.

(2)

Rotate thumb lever stop (7) to release thumb lever (2).

(3)

Depress thumb lever (2). NOTE

Hold open area indicator up while install finger assembly onto set master.

b.

(4)

Hook lower finger (5) assembly on lower trailing edge of set master (6).

(5)

Using rolling motion, engage upper finger (10) assembly under upper trailing edge of set master (6).

(6)

Release thumb lever (2).

(7)

Slightly rock HPT nozzle open area gage, 2C6505, from side to side to ensure ball contact (8) is seated against side rail of set master (6).

(8)

Adjust open area indicator (1) bezel so large pointer indicates 34.

Using HPT nozzle open area gage, 2C6505, measure HPT stage 1 nozzle as follows: (1)

Starting at No. 1 vane position, install HPT nozzle open area gage, 2C6505, onto HPT stage 1 nozzle as follows: (a) Depress thumb lever (2). (b) Position lower finger (5) assembly under trailing edge of vane. (c) Position upper finger (10) assembly under trailing edge of adjacent vane.

24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 427 00

(d) Rock HPT nozzle open area gage, 2C6505, forward until all probes make positive contact. Simultaneously, slide gage toward outer platform of vane segment until locating ball contact (8) contacts inside diameter (ID) of outer platform. (e) Release thumb lever (2) and HPT nozzle open area gage, 2C6505.

c.

d.

(2)

Tap lightly on HPT nozzle open area gage, 2C6505, to ensure constant reading and repeatability.

(3)

Read open area indicator (1).

(4)

Record reading in table 2.

(5)

Repeat steps (1) through (4) for all HPT stage 1 nozzle vanes. Recalibrate HPT nozzle open area gage, 2C6505, per step a. every 10 vanes checked.

Total flow area shall be 53.452 - 54.452 square in. (344.85 - 351.30 cm2). (1)

If total flow area is not within limits, replace HPT stage 1 vane nozzle segments, as required, to meet limits.

(2)

If total flow area specifications cannot be met, replace HPT stage 1 nozzle.

When not in use, maintain HPT nozzle open area gage, 2C6505, as follows: (1)

Ensure HPT nozzle open area gage, 2C6505, is stored away from dust, moisture, grit, and lubricants.

(2)

Using clean dry shop air, clean HPT nozzle open area gage, 2C6505, if mechanism becomes sluggish.

(3)

Recalibrate set master annually. Contact GE M&I for specific instructions on source of annual calibration.

25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. HPT Nozzle Open Area Gage, 2C6505 (Sheet 1 of 2) 26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 427 00

Figure 3. HPT Nozzle Open Area Gage, 2C6505 (Sheet 2 of 2)

27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Stage 1 Nozzle Open Area Work Sheet

Nozzle Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Sub Total

Open Area

Nozzle Number 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Sub Total

Open Area

Total Open Area = __________________________________________

28 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 2 NOZZLE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 16 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 16 ................. 0 Alphabetical Index Page

Subject High Pressure Turbine Stage 2 Nozzle Inspection............................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure turbine (HPT) stage 2 nozzle assembly.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II High Pressure Turbine Stage 2 Nozzle Assembly Replacement

GEK 105054

3.

Support Equipment. None required.

4.

Consumable Material.

5.

SWP 201 01

Nomenclature

Part No./Specification

Weld Filler Material

AMS 5786

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Turbine Stage 2 Nozzle Inspection. CAUTION

a.

•

IF ANY HPT INTERSTAGE AIR SEAL SEGMENT REQUIRES REPLACEMENT, HPT STAGE 2 NOZZLE ASSEMBLY SHALL BE REPLACED.

•

IF ANY HPT STAGE 1 OR 2 SHROUD SEGMENT REQUIRES REPLACEMENT, HPT STAGE 2 NOZZLE ASSEMBLY SHALL BE REPLACED.

Inspect HPT stage 2 nozzle per table 1 and figure 1. Table 1. HPT Stage 2 Nozzle Assembly

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

COOLING AIR TUBES 1. All Areas for: a. Cracks Not serviceable Not repairable b. Wear Not serviceable Not repairable HPT STAGE 2 NOZZLE SUPPORT ASSEMBLY 1. All Body Surface Area for: a. Cracks Not serviceable Not repairable

b.

Nicks and scratches

c.

Bulges and dents

d.

Plugged cooling air holes

Any number, any length 0.016 in. (0.40 mm) deep. Remove high metal from mating surfaces Three bulges or dents, 0.50 in. (12.7 mm) diameter, 0. 19 in. (4.8 mm) deep. No high metal allowed on mating surfaces Not serviceable

Not repairable

On-Site Corrective Action

Replace cooling tube Replace cooling tube

Replace HPT stage 2 nozzle per SWP 201 01 Replace HPT stage 2 nozzle per SWP 201 01

Any amount that will not affect assembly

Bench high metal on mating flanges mating surfaces or replace part

Any number

Clear holes

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. HPT Stage 2 Nozzle Support Flange for: a.

Circumferential cracks

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Radial cracks

Two radial cracks from boltholes inward, if separated by minimum of five boltholes

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Nicks and scratches

Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal from mating surface

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

d.

Missing or chipped thermal sprayed coating

10 percent may be missing

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

3. Rear Mounting Flange for: a.

Cracks extending from boltholes to edge of flange

Two radial cracks, if separated by minimum of five boltholes

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Nicks, scores, and scratches

Any number, 0.020 in. (0.50 mm) deep, after removal of high metal. Shall not extend more than 75 percent across surface

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Air Seal for: a.

Wear on wear strip

0.020 in. (0.50 mm) deep, if outside diameter (OD) is not less than 18.223 in. (462.86 mm) radius

Any amount

Re-form air seal to 36.446 in. (925.72 mm) diameter at wear strip or replace HPT rotor and HPT stage 2 nozzle

b.

Loose tack weld at support to seal junction

Not serviceable

Any amount

Tack-weld

c.

Circumferential cracks

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

d.

Axial cracks in saw cuts

One per saw cut, 0.25 in. (6.3 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

e.

Deformed wear strip

Not serviceable

Any amount, if weld is sound

Straighten or hand blend to smooth contour

f.

Deformed, missing, or worn seal strips or clips

Any amount not worn through. No loose or missing clips. Deformation allowed, if slot is sealed

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

g.

Burns or erosion

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

5. Shroud Stop for: a.

Cracks

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Wear

Any amount, 0.010 in. (0.25 mm) deep

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

6. Ferrule for: a.

Nicks and scratches

Any number, 0.040 in. (1.01 mm) deep, after removal of high metal

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Tack weld loose

One tack weld loose per ferrule

Any amount

Weld using AMS 5786 filler material

5 percent may be missing

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

7. Surface AV for: a.

Missing hard coat

FORWARD STAGE 2 SHROUD SUPPORT 1. All Areas for: a.

Circumferential cracks

Not serviceable

Not repairable

Replace forward shroud support segment

b.

Radial cracks

Two cracks from bolthole to OD of support. One crack at slot, 0.38 in. (9.6 mm) long

Not repairable

Replace forward shroud support segment

c.

Wear on mounting support

Any amount, 0.010 in. (0.25 mm) deep up to 1.00 in. (25.4 mm) from ends, 0.030 in. (0.76 mm) deep

Not repairable

Replace forward shroud support segment

d.

Distortion

Not serviceable

Any amount, if no cracks result from rework

Mechanically straighten. Inspect for cracks

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

AFT STAGE 2 SHROUD SUPPORT 1. Area G for: a.

Cracks from boltholes

Ten cracks, 0.25 in. (6.3 mm) long, if crack does not connect with slot

Not repairable

Replace aft shroud support

b.

Cracks from slot hole

One per slot, 0.25 in. (6.3 mm) long two per slot 0.150 in. (3.81 mm) long

Not repairable

Replace aft shroud support

c.

Cracks in plate

Ten cracks, 0.25 in. (6.3 mm) long

Not repairable

Replace aft shroud support

d.

Wear

Any amount, 0.005 in. (0. 12 mm) deep

Not repairable

Replace aft shroud support

2. Aft Mounting Supports for: a.

Cracks

Three axial cracks, 0.25 in. (6.3 mm) long separated by at least 2.0 in. (50.8 mm). No circumferential cracks allowed

Not repairable

Replace aft shroud support

b.

Wear on shroud track mating surface

Any amount, 0.010 in. (0.25 mm) deep, after removal of high metal

Not repairable

Replace aft shroud support

c.

Corrosion or burning

0.020 in. (0.50 mm) deep in area not greater than 0.25 in. (6.3 mm) by 0.25 in.(6.3 mm), 11 areas maximum

Not repairable

Replace aft shroud support

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

HPT STAGE 2 SHROUD 1. Mounting Supports for: a.

Cracks

Accept axial cracks if spaced 6.00 in. (152.4 mm) apart and do not extend into radial rib

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Wear on mating surface

Any length, 0.005 in. (0. 12 mm) deep, 0.010 in. (0.25 mm) deep for total length of 1.00 in. (25.4 mm)

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Bent edge on support

Not serviceable

0.06 in. (1.5 mm) from original for cracks

Mechanically straighten. Inspect contour

d.

Dents

0.020 in. (0.50 mm) deep, if it can be assembled

Dents up to 1.00 in. (25.4 mm) long are acceptable, if removal of protrusion does not thin flange to less than 50 percent of original flange thickness

Remove protrusion by blending

e.

Nicks and scores

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal

Any number, 0.020 in. (0.50 mm) deep

Blend to remove damage

f.

Distortion and/or waviness

Acceptable if proper assembly can be accomplished

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

2. Backing Strip for: a.

Circumferential cracks

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Backing Strip for: - (Cont.) b.

Axial cracks in backing strips

One crack per segment 0.50 in. (12.7 mm) long; four cracks per segment 0.25 in. (6.3 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Nicks, dents, and scores

Any number, 0.03 in. (0.7 mm) deep

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

3. Abradable Surface for: a.

Wear track

0.25 in. (6.3 mm) segment

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Positive metal due to blade rub

0.010 in. (0.25 mm) metal build up on two shroud segments per assembly

Any amount, if not more than 0.025 in. (6.3 mm) into abradable surface, after removal of positive metal

Blend

c.

Erosion or damage

0.050 in. (1.27 mm) deep, accumulation up to 30 percent of surface

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

d.

Loosened or missing filler exposing backing strip

75 percent in row of honeycomb cells adjacent to both forward and aft rails and 50 percent in the first and second row of honeycomb cells adjacent to both side plates. Three may be missing or loose at other places

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

4. Gas Face for:

a.

Radial cracks

Three per segment, 0.20 in. (5.0 mm) long, separated by 0.50 in. (12.7 mm)

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Erosion and/or missing metal

0.020 in. (0.50 mm) deep by 2.00 in. (50.8 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Circumferential cracks

Two per segment, 0.100 in. (2.54 mm) long, if they do not intersect radial cracks

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

0.020 in. (0.50 mm) deep, full length of segment, or 0.03 in. (0.7 mm) deep, 4.00 in. (101.6 mm) long per segment

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

5. Filled Honeycomb for: a.

Wear track

NOTE The cumulative total of all axial and circumferential areas of damage shall not exceed 1.00 sq in. (25.4 sq mm) per shroud segment. b.

Axial damage

Any number of scores not extending into backing strip, if cumulative total areas for damage does not exceed 1.00 sq in. (6.4 cm2) per segment or 2.00 sq in. (12.9 cm2) cumulative for entire shroud assembly

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

5. Filled Honeycomb for: - (cont.) c.

Circumferential damage caused by foreign objects

Any amount, if no one area of damage exceeds 0.10 in. (2.5 mm) wide for entire length of shroud segment or 0.20 in. (5.0 mm) wide per shroud segment and does not extend into backing strip

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

d.

Missing filler exposing backing strip

A total of 65 cells may be missing or 75 percent in row of honeycomb cells adjacent to both forward and aft rails and 50 percent in the first and second row of honeycomb cells adjacent to both side plates

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

e.

Cracks in abradable material

Any number, 0.50 in. (12.7 mm) long, if cumulative length does not exceed 1.50 in. (38.1 mm)

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

INTERSTAGE STATIONARY AIR SEAL 1. Honeycomb for: a.

Annular wear groove

One per groove, 0.25 in. (6.3 mm) wide, not to exceed 0.13 (3.3 mm) deep

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Honeycomb for: - (cont.) b.

Corner cell ribs dented or bent

Section of first cell rib may be dented 1.00 in. (25.4 mm) long, second cell rib 0.75 in. (19.0 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Cell damage/ erosion

Any number of isolated cell areas of 0.50 in. (12.7 mm) square

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

2. Housing for: a.

Axial cracks

Two axial cracks, 1.00 in. (25.4 mm) long, not within 2.0 in. (50.8 mm) of end

b.

Circumferential cracks

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Damage or distortion at cooling slots

Any amount. No cracks allowed

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

STAGE 1 TURBINE SHROUDS 1. Mounting Supports for: a.

Cracks

Accept axial cracks if spaced 6.00 in. (152.4 mm) apart and do not extend into radial rib

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Wear on mating surface

Any length, 0.005 in. (0.12 mm) deep, 0.010 in. (0.25 mm) deep for total length of 1.00 in. (25.4 mm)

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Mounting Supports for: - (cont.) c.

Bent edge on support

Not serviceable

0.06 in. (1.5 mm) from original contour

Mechanically straighten. Inspect for cracks

d.

Dents

0.020 in. (0.50 mm) deep, if it can be assembled

Dents up to 1.00 in. (25.4 mm) long are acceptable, if removal of protrusion does not thin flange to less than 50 percent of original flange thickness

Remove protrusion by blending

e.

Nicks and scores

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal

Any number, 0.020 in. (0.50 mm) deep

Blend to remove

f.

Distortion and/or waviness

Acceptable, if proper assembly can be accomplished

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

2. Backing Strip for: a.

Circumferential cracks

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Axial cracks in backing strips

One crack per segment, 0.50 in. (12.7 mm) long; four cracks per segment 0.25 in. (6.3 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Nicks, dents, and scores

Any number, 0.03 in. (0.7 mm) deep

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Abradable Surface for: a.

Wear track

0.25 in. (6.3 mm) deep full length of segment

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Positive metal due to blade rib

0.010 in. (0.25 mm) metal buildup on two shroud segments per assembly

Any amount, if not more than 0.025 in. (6.3 mm) into abradable surface after removal of positive metal

Blend

c.

Erosion or damage at shroud edges

0.10 in. (2.54 mm) deep, accumulation up to 10 percent of surface

Not repairable

Replace HPT rotor and HPT stage 2 nozzle

d.

Erosion/ burning exposing backing strip

Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

4. Gas Face for: a.

Radial cracks

Three per segment, 0.20 in. (5.0 mm) long, separated by 0.50 in. (12.7 mm)

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Erosion and/or missing metal

0.020 in. (0.50 mm) deep by 2.00 in. (50.8 mm) long

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

c.

Circumferential cracks

Two per segment, 0.100 in. (2.54 mm) long, if they do not intersect with radial cracks

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 428 00

Figure 1. HPT Stage 2 Nozzle Assembly (Sheet 1 of 2) 15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 428 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. HPT Stage 2 Nozzle Assembly (Sheet 2 of 2) 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES TURBINE MID FRAME INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 20 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 19 ................. 0 20 Blank ........... 0 Alphabetical Index Page

Subject Turbine Mid Frame Inspection...........................................................................................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, turbine mid frame (TMF).

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II Turbine Mid Frame Replacement

GEK 105054 WP 200 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Turbine Mid Frame Inspection a.

Remove TMF per WP 200 00.

b.

Inspect TMF per table 1 and figures 1 through 4. Table 1. Turbine Mid Frame Inspection On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

CASE 1. Specific Areas to be Inspected for Cracks: a.

b.

Indications in weld/heat affected zone areas

Indications in parent metal (outside weld/heat affected zone)

Indication no longer than 0.10 inch (2.5 mm)

Not repairable

Replace TMF per WP 200 00

Indications confined to weld or heat affected zone within 0.10 inch (2.5 mm) of weld line

Not repairable

Replace TMF per WP 200 00

Indications transverse to weld line in heat affected zone

Not repairable

Replace TMF per WP 200 00

Min spacing between indications: two times max adjacent indication dimension

Not repairable

Replace TMF per WP 200 00

Indications no longer than 0.030 inch (0.78 mm)

Not repairable

Replace TMF per WP 200 00

Indications 0.030 to 0.060 inch (0.76 to 1.52 mm) long, not interpreted as cracks

Not repairable

Replace TMF per WP 200 00

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Specific Areas to be Inspected for Cracks: - (cont.) Indications in parent metal (outside weld/heat affected zone) (cont.)

Min spacing between indications: two times max adjacent indication dimension

Not repairable

Replace TMF per WP 200 00

2. Hat Sections (Fore and Aft) for: a.

Fillet weld cracks

Not serviceable in excess of limits in 1. above

Not repairable

Replace TMF per WP 200 00

b.

Seam weld cracks

Not serviceable in excess of 2.0 inches (50.8 mm) per segment

Not repairable

Replace TMF per WP 200 00

c.

Parent metal cracks (neutral areas only

Not serviceable in excess of limits in 1. above

Not repairable

Replace TMF per WP 200 00

Not serviceable

Not repairable

Replace TMF per WP 200 00

Not serviceable

Not repairable

Replace TMF per WP 200 00

Not serviceable

Not repairable

Replace TMF per WP 200 00

3. Forward Flange for: a.

Circumferential weld cracks

4. Aft Flange for: a.

Circumferential weld cracks

5. Casing Strut Pads for: a.

Butt weld cracks

6. Instrumentation (T5.4 and P5.4) Bosses for: a.

Cracks

One crack, 0.25 inch (6.3 mm) long. One boss per frame may be cracked

Not repairable

Replace TMF per WP 200 00

b.

Thread damage

Not serviceable

One complete thread may be removed

Chase threads

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

7. All Other Casing Areas for: a.

Axial welds/parent metal cracks

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Nicks, scores, and scratches

Any number, any length, 0.016 inch (0.40 mm) deep after removal of high metal, if defects do not cross completely across sealing surface

Not repairable

Replace TMF per WP 200 00

c.

Dents

Any number smooth contour dents 0.25 inch (6.3 mm) deep, except on interface sealing surface

Not repairable

Replace TMF per WP 200 00

d.

Local distortion

Any number, 0.20 inch (5.0 mm) deep, except on interface sealing surface

Not repairable

Replace TMF per WP 200 00

8. Case Strut Pads for: a.

Cracks

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Bent lugs

Not serviceable

Not repairable

Replace TMF per WP 200 00

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

LINER 1. All Surfaces (Unless Otherwise Specified) for: a.

Cracks in skin (no separation through aft ring)

Any number, not exceeding 2.0 inches (50.8 mm) length, and not joining with adjacent cracks. Monitor for crack propagation by borescope inspection at each opportunity, but not later than 500 hours of operation

Not repairable

Replace TMF per WP 200 00

b.

Missing material

Not serviceable

Not repairable

Replace TMF per WP 200 00

c.

Buckling or distortion

Any amount, 0.25 inch (6.3 mm) from original contour, 0.125 inch (3.17 mm) buckles on leading edge

Not repairable

Replace TMF per WP 200 00

d.

Nicks, scores, and scratches

Any number, any length, 0.016 inch (0.40 mm) deep, after removal of high metal

Not repairable

Replace TMF per WP 200 00

e.

Dents

Any number smooth contour dents 0.25 inch (6.3 mm) deep, except on sealing surface or surface evidencing hot spots

Not repairable

Replace TMF per WP 200 00

f.

Hot spots

Serviceable, if metal not crazed

Not repairable

Replace TMF per WP 200 00

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Surfaces (Unless Otherwise Specified) for: - (cont.) g.

Wear on ID of fairing

50 percent of stock thickness

Not repairable

Replace TMF per WP 200 00

2. Inner Rear Seals for: a.

Gap at seal opening

1.0 sq in. (25.4 sq mm) max

Any amount

Re-form seal

b.

Broken or missing segments

Not serviceable

Not repairable

Replace TMF per WP 200 00

3. Liner Deflectors for: a.

Missing deflector

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Cracked or broken deflector

Not serviceable

Not repairable

Replace TMF per WP 200 00

Not serviceable

Not repairable

Replace TMF per WP 200 00

Not repairable

Replace TMF per WP 200 00

Not repairable

Replace TMF per WP 200 00

STRUT END CAPS 1. Gasket for: a.

Visible damage to gasket or loss of gasket material

2. Flanges (Cap and Tube) and Cap Lugs for: a.

Distortion, outof-flat flange and bent cap lugs

Not serviceable

LINER SUPPORT 1. All Areas Unless Otherwise Specified for: a.

Cracks (1)

Inner Support

Not serviceable

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. All Areas Unless Otherwise Specified for: - (cont.) (2)

Outer Support

Accept one crack per bolthole 0.50 inch (12.7 mm) long, provided cracked boltholes are separated by one uncracked hole

Not repairable

Replace TMF per WP 200 00

b.

Nicks, scores, and scratches

Any number, any length 0.016 inch (0.40 mm) deep, after removal of high metal

_

Blend

c.

Dents

Any number smooth contour dents 0.125 inch (3.17 mm) deep, except on mating (sealing) surface

Not repairable

Replace TMF per WP 200 00

2. Liner Support Stops (For Stage 2 HPT Shroud) for: a.

Cracks

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Missing stops

Maximum of 44 stops may be missing if no more than 6 are adjacent

Not repairable

Replace TMF per WP 200 00

c.

Bent

Not serviceable

Not repairable

Replace TMF per WP 200 00

3. Swaged Bushing for: a.

Cracks

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Wear at strut pad/case holes

Local fretting or grooving up to 0.010 inch (0.25 mm) deep

Not repairable

Replace TMF per WP 200 00

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

3. Swaged Bushing for: - (cont.) c.

Pickup and high metal

Not serviceable

Any amount

Remove high metal using fine file or stone

C-SUMP HOUSING 1. No. 5 Bearing Housing Bore for: a.

Wear and outer surface distress (nicks, scratches, and dents)

Any number, 0.010 in. (0.25 mm) deep max, after removal of high metal

Not repairable

Replace TMF per WP 200 00

b.

Surface damage

Same as a.

Not repairable

Replace TMF per WP 200 00

2. No. 6 Bearing Housing Bore for: (LM2500+ Model PK Only) a.

Wear and outer surface distress (nicks, scratches, and dents)

Any number, 0.010 in. (0.25 mm) deep max, after removal of high metal

Not repairable

Replace TMF per WP 200 00

b.

Surface damage

Same as a.

Not repairable

Replace TMF per WP 200 00

AFT OUTER AIR SEAL (LM2500+ Model PK only) 1. Flange for: a.

Cracks

One crack per bolthole from hole to outer edge of flange; max of 12 holes. No more than 3 holes in a row with cracks. No missing pieces allowed

Not repairable

Replace seal

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Flange for: - (cont.) b.

Nicks, dents, and scratches

Any number, 0.020 inch (0.50 mm) deep, after removal of high metal

Not repairable

Replace seal

c.

Wear

0.005 inch (0.12 mm) deep

0.010 inch (0.25 mm) deep

Blend smooth

d.

Distortion

0.020 inch (0.50 mm) out-ofcontour maximum of 2.0 inches (50.8 mm) in individual area, total not to exceed 10 inches (254 mm) provided proper assembly can be accomplished

Not repairable

Replace seal

2. Backing Strip for: a.

Cracks

Any number axial cracks 0.5 inch (12.7 mm) long and 1.0 inch (25.4 mm) apart, not across edges

Not repairable

Replace seal

b.

Nicks, dents, and scores

Any number, 0.020 inch (0.50 mm) deep

Not repairable

Replace seal

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Backing Strip for: - (cont.) c.

Distortion

0.0625 inch (1.587 mm) out-ofcontour, maximum of 4.0 inches (101.6 mm) in individual area, total not to exceed 20 inches (508 mm), if proper assembly can be accomplished

Not repairable

Replace seal

3. Honeycomb for: a.

Wear

Track not to exceed 0.150 inch (3.81 mm) maximum depth, any width. Track may run off edge of honeycomb

Not repairable

Replace seal

b.

Damage caused by foreign objects or handling

Not to exceed 10 percent of total circumferential length 25 percent of honeycomb width and not into backing strips after removal of folded edges

Not repairable

Replace seal

c.

Loose or unbonded cells

Not serviceable

Not repairable

Replace seal

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

LOW PRESSURE TURBINE (LPT) NOZZLE SUPPORT (LM2500+ MODEL PK ONLY) 1. All Surfaces Unless Otherwise Specified for: a.

Cracks

Not serviceable

Not repairable

Replace TMF per WP 200 00

b.

Nicks or scores

Any number, any length, 0.0156 inch (0.396 mm) deep, after removal of high metal

Not repairable

Replace TMF per WP 200 00

c.

Dents

Any number smooth contour dents 0.125 inch (3.17 mm) deep

Not repairable

Replace TMF per WP 200 00

2. Seal for: a.

Distortion

Any amount, provided mating part can be assembled

Any amount

Re-form

b.

Wear

50 percent of stock thickness

Not repairable

Replace TMF per WP 200 00

Not serviceable

Not repairable

Replace TMF per WP 200 00

3. Safety Wire Tabs for: a.

Broken/ missing

OUTER NOZZLE SUPPORT (LM2500+ MODEL PK ONLY) 1. Pins for: a.

Loose or missing

Not serviceable

Not repairable

Replace outer nozzle support

b.

Bent

Not serviceable

Any amount

Straighten pin

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. All surfaces for: a.

Axial and radial cracks

Any number, any length in axial or radial direction. Radial cracks may sever support if each remaining segment contains a minimum of two counter-sunk. screw holes used to mount nozzle support to TMF

Not repairable

Replace aft ring

b.

Circumferential cracks

Not serviceable

Not repairable

Replace aft ring

c.

Distortion

Acceptable if proper assembly can be made

Not repairable

Replace aft ring

d.

Nicks and scores

Any number, 0.0312 inch (0.792 mm) deep, remove high metal

Not repairable

Replace support

e.

Dent

Any number, 0.0312 inch (0.792 mm) deep

f.

Wear

0.010 inch (0.25 mm) deep on outside diameter (OD) of axial flange, 0.095 inch (2.41 mm) minimum flange thickness

0.020 inch (0.50 mm) deep on OD of axial flange

Blend smooth

HPT ADAPTER (LM2500+ MODELS GK, GV, AND PV ONLY) 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace HPT adapter

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Mating Surfaces for: a.

Pickup and high metal

Not serviceable

Any amount

Remove high metal

b.

Nicks, dents, and scratches

Any number, any length, 0.030 in. (0.76 mm) deep, after removal of high metal, if defect does not extend completely across mating surface

Any number

Blend to original contour

Ten holes, but not more than two adjacent boltholes

Any amount, but not more than four adjacent boltholes

Replace HPT adapter

3. Boltholes for: a.

Outer flange bolthole cracks

4. Gang Channel Nuts for: a.

Loose or unseated retaining screws

Not serviceable

Any number

Tighten screw or replace screw. Screwhead not to extend beyond flange surface

b.

Loss of self locking quality or missing nuts

Not serviceable

Any number

Replace HPT adapter

Any number not exceeding 3.0 in. (76 mm) length

Replace aft cover

AFT COVER (LM2500+ Model GK Only) 1. All Areas for: a.

Cracks

Not serviceable

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

2. Mating Surface for: a.

Pickup and high metal

Not serviceable

Any amount

Remove high metal

b

Nicks, dents, and scratches

Any number, any length, 0.030 in.(0.76 mm) deep, after removal of high metal, if defect does not extend completely across mating surface

Any number

Blend to remove damage

Ten holes max, but not more than two cracks adjacent boltholes

Any amount, but not more than four adjacent boltholes

Replace aft cover

3. Boltholes for: a.

Outer flange bolthole cracks

15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. TMF-LM2500+ Model GK Only 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 429 00

Figure 2. TMF-LM2500+ Model PK Only 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 429 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. TMF-LM2500+ Models GV and PV Only 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 429 00

Figure 4. TMF Casing-to-Casing Butt Weld Areas

19/(20 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 430 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR VARIABLE STATOR VANE SHROUDS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 ................... 0 Alphabetical Index Page

Subject High Pressure Compressor Variable Stator Vane Shrouds Inspection............................

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 430 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the inspection of the high pressure compressor (HPC) variable stator vane (VSV) shrouds.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Shrouds Replacement

GEK 105054 WP 211 00

3.

Support Equipment. None required.

4.

Consumable Material. None required.

5.

Expendable Material. None required.

WP 213 00

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 430 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

High Pressure Compressor Variable Stator Vane Shrouds Inspection. a.

Remove HPC stator casings per WP 211 00.

b.

Remove VSV shrouds per WP 213 00. NOTE The front and rear halves of each VSV shroud 180 degree segment are machined as an assembly, and shall be maintained as matched sets.

c.

Inspect VSV shrouds per table 1. Table 1. HPC VSV Shrouds Inspection On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. Inlet Guide Vane (IGV), Stage 0, Stage 1, and Stage 2 Shrouds for: a.

Cracks

Not serviceable

Not repairable

Replace shrouds

b.

Nicks and scratches

Any number, 0.0156 in. (0.396 mm) deep, after removal of high metal, with 0.030 in. (0.76 mm) minimum radius at bottom

Any number, 0.030 in. (0.76 mm) deep, 2.0 in. (50.8 mm) long, with 0.030 in. (0.76 mm) minimum radius at bottom

Remove high metal, blend out with 0.030 in. (0.76 mm) minimum radius tool, or replace shroud

c.

Dents

Any number, 0.0625 in. (1.587 mm) deep, if there are no sharp edges or abrupt change in contour

Not repairable

Replace shroud

d.

Distortion (warped)

Acceptable, if they can be properly assembled, do not interfere with VSV operation, and specified rotor clearances can be maintained

Not repairable

Replace shroud

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 430 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC VSV Shrouds Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect

On-Site Maximum Repairable Limits

On-Site Corrective Action

1. IGV, Stage 0, Stage 1, and Stage 2 Shrouds for: - (cont.) e.

Variable vane tip rub on shroud outside diameter (OD)

Any amount, 0.0156 in. (0.396 mm) deep, after removal of high metal

Not repairable

Remove high metal or replace shroud

f.

Seal rub

0.015 in. (0.38 mm) deep, full circumference

Any amount, 0.030 in. (0.76 mm) deep

Remove high metal or replace shroud

g.

Fretting on end faces

Any amount, 0.010 in. (0.25 mm) deep

Any amount

Remove high metal

h.

IGV shroud forward lip inside diameter (ID) wear

Any amount to 0.045 in. (1.14 mm) min wall thickness

Not repairable

Replace shroud

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE THRUST BALANCE CAVITY PRESSURE SYSTEM ORIFICE PLATE SELECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 8 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0

Alphabetical Index Subject

Page

Power Turbine Thrust Balance Cavity Pressure System Orifice Plate Selection. ..........

3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for selecting proper size power turbine (PT) thrust balance cavity pressure system orifice plate to maintain engine within preferred operating range. The orifice plate is used to adjust the thrust balance cavity pressure.

2.

3.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I LM2500 + SAC System Description Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 Chapter 5 Chapter 7 GEK 105054 WP 002 00 GEK 105055

Support Equipment. Nomenclature Excel worksheet - No.7B Trust Balance Orifice Selection

4.

5.

Part No. -

Consumable Material. Nomenclature

Part No./Specification

Thread Lubricant

GE Spec A50TF201 or MIL-T-5544

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Orifice Plate Square Seal Gasket

44-57 44-56

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Power Turbine Thrust Balance Cavity Pressure System Orifice Plate Selection. NOTE

•

Maintenance of PT thrust balance cavity pressure in the preferred operating range is required to ensure No. 7B bearing life. Refer to GEK 105054, Volume I, Chapter 5, for monitoring requirements.

•

During initial buildup of gas turbine, PT thrust balance cavity pressure is adjusted into operating range with the proper size orifice plate. Due to changes in balance piston seal leakage, periodic orifice sizing and adjustment of PT balance piston system cavity pressure are required.

a.

Comply with all instructions contained in WP 002 00.

b.

Check and record part number of PT balance piston system orifice plate (3, figure 1). Determine corresponding orifice plate size from table 1.

c.

Use PT thrust balance cavity pressure tap (figure 2) located on turbine rear frame (TRF) number 2 strut. If tap is not already in use, remove cap and install suitable high temperature hose with 0-200 psia (0-1379.0 kPa) range gage or transducer attached. Tighten hose B-nut to 180-200 lb in. (20.4-22.5 N⋅m) of torque. Table 1. PT Balance Piston Orifice Plate Size Part No. 1792M79P01 1792M79P02 1792M79P03 1792M79P04 1792M79P05 1792M79P06 1792M79P07 1792M79P08 1792M79P09 1792M79P10 1792M79P11 1792M79P12 1792M79P13 1792M79P14 1792M79P15 1792M79P16 1792M79P17 1792M79P18

Orifice Diameter 0.495-0.505 inch 0.515-0.525 inch 0.545-0.555 inch 0.575-0.585 inch 0.605-0.615 inch 0.635-0.645 inch 0.665-0.675 inch 0.695-0.705 inch 0.725-0.735 inch 0.755-0.765 inch 0.785-0.795 inch 0.815-0.825 inch 0.845-0.855 inch 0.875-0.885 inch 0.905-0.915 inch 0.935-0.945 inch 0.965-0.975 inch 0.995-1.005 inch

(12.58-12.82 mm) (13.09-13.33 mm) (13.85-14.09 mm) (14.61-14.85 mm) (15.37-15.62 mm) (16.13-16.38 mm) (16.90-17.14 mm) (17.66-17.90 mm) (18.42-18.66 mm) (19.18-19.43 mm) (19.94-20.19 mm) (20.71-20.95 mm) (21.47-21.71 mm) (22.23-22.48 mm) (22.99-23.24 mm) (23.75-24.00 mm) (24.51-24.77 mm) (25.27-25.53 mm) 3

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. PT Thrust Balance Air Supply Tubes 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. PT Thrust Balance Pressure Tap

d.

Start and operate gas turbine per Chapter 7 of GEK 105054, Volume I. Accelerate to obtain P5.4 pressure of 60 psia (413.7 kPa) or greater and stabilize. NOTE For a copy of NO.7B THRUST BALANCE ORIFICE SELECTION Excel spreadsheet, contact GE customer service.

e.

Record parameters required to calculate No. 7B thrust load. Input parameters into NO.7B TRUST BALANCE ORIFICE SELECTION Excel spreadsheet (figure 3) to verify orifice plate size.

f.

Shut down gas turbine per GEK 105054, Volume I, Chapter 7.

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. No.7B Thrust Balance Orifice Selection Worksheet (Example) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines g.

If necessary, replace orifice plate (3, figure 1) as follows: (1)

Remove self-locking nuts (1) and bolts (2) securing forward and aft sections of PT thrust balance air supply tubes (5 and 6) together.

(2)

Remove orifice plate (3) and square seal gaskets (4) from between forward and aft sections of PT thrust balance air supply tubes (5 and 6). NOTE

The replacement orifice plate must be installed correctly. The plate has an identification tab indicating forward and aft installation orientation. (3)

Install replacement orifice plate (3) and square seal gaskets (4) between forward and aft sections of PT thrust balance air supply tubes (5 and 6).

(4)

Lightly coat threads of four bolts (2) with thread lubricant.

(5)

Using bolts (2) and self-locking nuts (1), secure forward and aft sections of PT thrust balance air supply tube (5 and 6). Tighten nuts to 55-70 lb-in. (6.3-7.9 N⋅m) of torque.

h.

To determine if further adjustment is necessary, recheck PT thrust balance cavity pressure at the same P5.4 settings as used in step 6.e.

i.

Install cap (figure 2) on PT thrust balance cavity pressure tap, if used, as follows:

j.

(1)

Lightly coat cap threads with thread lubricant.

(2)

Install cap on PT thrust balance cavity pressure tap. Tighten cap to 180-200 lb in. (20.4-22.5 N⋅m) of torque.

Change alarm settings to comply with this work package. Proceed as follows: (1)

Make arrangements to collect and input the following parameters into the control system:

• P ambient (P0) in PSIA • Inlet pressure (P2) in PSIA • CDP pressure (PS3) in PSIA • No. 7B TBP Pressure (PABP) in PSIA • PT inlet pressure (P48 or P54) in PSIA • PT inlet temperature (T48 or T45) in degrees F • PT rotor speed (NPT) in RPM 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Calculate No.7B bearing load using the following equation:

No.7B load=-7127+641*P48-381*PABP+27.3*SQRT(NPT/SQRT(T48+459.7))*P48-360*(P0-14.696)

(3)

If No.7B load calculated in step 2 is greater than 8500, set off HIGH LOAD ALARM. If No.7B load calculated in step 2 is less than 8500, set off LOW LOAD ALARM. NOTE

For a copy of NO.7B TRUST BALANCE ORIFICE SELECTION Excel spreadsheet, contact GE customer service. (4) In the event of an either HIGH LOAD ALARM or LOW LOAD ALARM, resize orifice plate according to NO.7B THRUST BALANCE ORIFICE SELECTION Excel spreadsheet (figure 3).

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR/GAS TURBINE PRESERVATION, DEPRESERVATION, AND STORAGE MAINTENANCE (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 14 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 14 ................. 0 Alphabetical Index Subject

Page

Definitions. .......................................................................................................................... 4 Depreservation of Engine. .................................................................................................. 14 Noninstalled Engine Preservation For Indefinite Period. ................................................ 6 Installed Engine Preservation For 30 Days or Less.......................................................... 4 Installed Engine Preservation When Engine Cannot Be Motored................................... 4 Noninstalled Engine Preservation For Indefinite Period. ................................................ 6 Noninstalled Engine Preservation For 30 Days or Less. .................................................. 6 Oil Wetting of Engine Bearings.......................................................................................... 8

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for preserving and readying LM2500+ Models GK and GV gas generators and Model PK gas turbine. For LM2500+ Model PV gas turbine, preservation and depreservation instructions for the gas generator are per this work package. For LM2500+ Model PV gas turbine power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title

For LM2500+ Models GK and GV gas generators, Model PK gas turbine, and Model PV gas turbine gas generator only: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Water Wash WP 405 00 Gas Generator/Gas Turbine Shipping WP 502 00 Shipping Container Inspection and Reconditioning WP 504 00 Illustrated Parts Breakdown GEK 105055 For LM2500+ Model PV gas turbine power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment. Nomenclature

Part No.

Spline, Adapter, Manual or Aft Drive Pad Drive Motor, Electric (115 Vac) Drive Motor, Electric (220 Vac) Drive Motor, Electric (115 Vac/220 Vac) Stand, Portable Lubricating

1C8208G02 2C14764G01 2C14764G02 2C14764G05 Local Purchase

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 4.

Consumable Material. Nomenclature

Part No./Specification

Barrier Paper Desiccant Lubricating Oil

MIL-B-121 MIL-D-3464 MIL-L-23699 or MIL-L-7808 GE Spec D50TF6 or Brayco 599 736L680G01 R297P04 (Alt)

Rust Preventative Concentrate Safety Cable Safety Wire 5.

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing

TBP TBP TBP 8-96 8-153

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00 6.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Definitions. CAUTION ENGINE SHALL NOT BE STORED IN ANY MANNER THAT ALLOWS ROUTINE EXPOSURE TO OUTSIDE ELEMENTS.

7.

a.

Installed engine: An engine installed in the enclosure/package, with all service connections in place, capable of being started and run to idle level with no further connections required. The attached power turbine and/or accessories shall be capable of being rotated. The enclosure/package shall be weather-tight.

b.

Noninstalled engine: An engine installed in the enclosure/package, with partial or no service connections in place, incapable of being started without further maintenance. An engine installed in a maintenance dolly, or an engine installed in the shipping container, or any other condition not addressed by step a.

c.

Normal environment: Temperature 25 to 85°F (-4 to 29°C), relative humidity 25-65 percent.

Installed Engine Preservation For 30 Days or Less. a.

Comply with all instructions contained in WP 002 00. CAUTION ENSURE ATTACHED POWER TURBINE AND/OR ACCESSORIES ARE PRELUBRICATED OR DRIVE SHAFT IS DISCONNECTED PRIOR TO MOTORING ENGINE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO POWER TURBINE AND/OR ACCESSORIES.

8.

b.

Water-wash engine per WP 405 00.

c.

Motor engine for minimum of 3 minutes per GEK 105054, Chapter 7.

d.

Using moisture barrier paper, cover inlet and exhaust openings. Cover or plug all engine openings and unattached fittings.

Installed Engine Preservation When Engine Cannot Be Motored (Repeat Every 60 Days or Less). a.

Comply with all instructions contained in WP 002 00. NOTE For preservation periods that are 60 days or more, use of rust preventative concentrate is mandatory.

b.

Water-wash engine per WP 405 00.

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines c.

Using moisture barrier paper, cover inlet and exhaust openings. Cover or plug all engine openings and unattached fittings.

d.

Oil wet bearings per paragraph 12.

e.

At 30 day intervals: (1)

Remove moisture barrier paper, covers, and plugs installed on engine. CAUTION

9.

•

ENSURE ATTACHED POWER TURBINE AND/OR ACCESSORIES ARE PRELUBRICATED. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO POWER TURBINE AND/OR ACCESSORIES.

•

DO NOT EXCEED STARTER DUTY CYCLE WHEN MOTORING.

•

HYDRAULIC STARTER HAS NO DUTY CYCLE LIMITATIONS, HOWEVER, OIL TEMPERATURE SHALL BE MAINTAINED BELOW 140°F (60°C).

•

PNEUMATIC STARTER DUTY CYCLE IS AS FOLLOWS: 5 MINUTES ON, 2 MINUTES OFF, 5 MINUTES ON, 18 MINUTES OFF OR 10 MINUTES ON, 20 MINUTES OFF.

(2)

Motor engine for minimum of 3 minutes per GEK 105054, Chapter 7.

(3)

Using moisture barrier paper, cover inlet and exhaust openings. Cover or plug all engine openings and unattached fittings.

Installed Engine Preservation For Indefinite Period. a.

Comply with all instructions contained in WP 002 00. CAUTION FOR PRESERVATION PERIODS THAT EXTEND PAST 60 DAYS, USE OF RUST PREVENTATIVE CONCENTRATE IS MANDATORY.

b.

Add 5 percent (by volume) of rust preventative concentrate to lubricating oil tank, if not previously added, per packager’s manual.

c.

Perform paragraph 8, steps b. through e.

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

10. Noninstalled Engine Preservation For 30 Days or Less. a.

Comply with all instructions contained in WP 002 00. NOTE Step b. applies only if engine is stored in a shipping container.

b.

If possible, shipping container shall be stored in shaded area, away from direct sunlight, and within limits of normal environment.

c.

Maintain and update engine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions, oil wetting dates, and desiccant replacement.

11. Noninstalled Engine Preservation For Indefinite Period. a.

Comply with all instructions contained in WP 002 00.

b.

Maintain and update engine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions, oil wetting dates, and desiccant replacement.

c.

If engine is in shipping container, inspect container humidity indicator (figure 1) for color. Indicator shall appear blue, indicating safe humidity conditions. If indicator appears pink, proceed as follows: (1)

Remove shipping container cover per WP 502 00.

(2)

Replace desiccant per WP 502 00.

(3)

Reinstall shipping container cover per WP 502 00.

(4)

At next 30 day inspection, note humidity indicator appearance. If indicator is any color other than blue, proceed as follows: (a) Repeat substeps (1) and (2). (b) Inspect container cover seal per WP 504 00. Replace seal if required. (c) Oil wet bearings per paragraph 12. (d) Reinstall shipping container cover per WP 502 00.

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 500 00

Figure 1. Humidity Indicator - LM2500+ Shipping Container 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

12. Oil Wetting of Engine Bearings. a.

Comply with all instructions contained in WP 002 00.

b.

Perform oil wetting of engine bearings as follows: (1)

Remove moisture barrier paper, covers, and plugs installed on engine. CAUTION

SHUT OFF MAIN LUBE SUPPLY LINE PRIOR TO DISCONNECTING IF DISCONNECTING FROM ENGINE LUBE AND SCAVENGE PUMP. (2)

Connect portable lubricating stand supply and scavenge pumps (figures 2 and 3) as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) If connected, disconnect lube supply hose from lube and scavenge pump inlet supply tube. Drain residual oil into appropriate container. (b) Connect portable lubricating stand supply line to lube and scavenge pump inlet supply tube. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. (c) If connected, disconnect hose from lube and scavenge pump scavenge discharge tube. Drain residual oil into appropriate container. (d) Cap scavenge discharge tube. (e) Remove safety wire and remove drain plug from forward side of accessory gearbox. Discard preformed packing. (f) Install fitting into accessory gearbox drain hole. (g) Connect portable lubricating stand scavenge line to fitting in accessory gearbox drain hole. (h) For gas generators, remove safety wire and remove B- and C-sump scavenge screens from bottom of lube and scavenge pump. (i) For gas turbines, remove safety wire and remove B-, C-, and D-sump scavenge screens from bottom of lube and scavenge pump.

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 500 00

Figure 2. Typical Portable Lubricating Stand-Gas Generator 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. Typical Portable Lubricating Stand-Gas Turbine 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (j)

Install fittings into ports in lube and scavenge pump where sump screens have been removed.

(k) Connect portable lubricating stand scavenge lines to fittings in lube and scavenge pump sump ports. (3)

Install spline adapter and electric drive motor as follows: (a) Remove nuts and washers that secure aft drive pad cover onto accessory gearbox. Remove cover and discard preformed packing. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (b) Using lubricating oil, lubricate spline adapter, 1C8208. (c) Using washers and nuts, secure spline adapter, 1C8208, into aft drive spline. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (d) Install electric drive motor, 2C14764, onto aft drive pad. Align square drive of drive motor with spline adapter, 1C8208. (e) Using washers and bolts, secure drive motor to accessory gearbox aft drive pad. Tighten bolts to 420-510 lb in. (47.5-57.6 N⋅m) of torque. (f) Connect drive motor to applicable power source. (4)

Oil wet bearings as follows: NOTE

The use of rust preventative concentrate is optional if preservation period is less than 60 days. (a) Add 5 percent (by volume) of rust preventive concentrate to lubricating oil tank of portable lube stand.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

ENSURE PORTABLE LUBRICATING STAND SCAVENGE LINES SHOW VISIBLE FLOW THROUGH VIEWING WINDOWS. IF FLOW IS NOT OBSERVED, STOP PORTABLE LUBRICATING STAND AND SCAVENGE PUMPS. CHECK ALL HOSES AND FITTINGS FOR LEAKS. FAILURE TO COMPLY WILL RESULT IN OVERFLOW OF ENGINE OIL SUMPS. (b) Start portable lubricating stand supply and scavenge pumps. Ensure supply pressure is regulated to 5-10 psi (34.5-68.9 kPa). Ensure lubricating oil supply oil temperature is 60 to 100°F (15.6 to 37.7°C). (c) Using drive motor, 2C14764, rotate high pressure compressor (HPC) rotor in forward direction for minimum of two rotations (12-15 minutes) at maximum RPM. If installed, rotate power turbine by hand using forward adapter. (d) Stop portable lubricating stand supply pump. (e) Run portable lubricating stand scavenge pump until no oil flow is visible in scavenge lines viewing windows. (f) Stop portable lubricating stand scavenge pump. (5)

Disconnect portable lubricating stand supply and scavenge pumps as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Remove portable lubricating stand scavenge lines from sump port fittings in lube and scavenge pump and accessory gearbox drain fitting. Drain residual oil into appropriate container. (b) Using lubricating oil, lubricate new preformed packings for sump screens and accessory gearbox drain plug. (c) Install preformed packing onto sump screens and accessory gearbox drain plug. (d) Install drain plug into accessory gearbox. Tighten drain plug to 270-300 lb in. (30.6-33.9 N⋅m) of torque and safety wire. (e) For gas generators, install B- and C-sump inlet screens into lube and scavenge pump sump ports. Tighten screens to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety wire.

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

(f) For gas turbines, install B-, C-, and D-sump inlet screens into lube and scavenge pump port. Tighten screens to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety wire. (g) Remove cap from lube and scavenge pump scavenge discharge tube. (h) Connect hose to lube and scavenge pump scavenge discharge tube, if applicable. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. (i) Disconnect portable lubricating pump supply line from lube and scavenge pump inlet. Drain residual oil into appropriate container. (j)

Connect hose to lube and scavenge pump inlet supply tube, if applicable. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque.

(k) If applicable, open lube tank supply line per packager’s manual. (6)

Remove spline adapter and electric/pneumatic drive motor as follows: (a) Remove bolts and washers that secure electric drive motor, 2C14764, onto aft drive pad of accessory gearbox. Remove drive motor. (b) Remove nuts and washers that secure spline adapter, 1C8208, into aft drive spline of accessory gearbox. Remove spline adapter. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (c) Using lubricating oil, lubricate preformed packing. (d) Install preformed packing into groove on aft drive pad cover. (e) Install aft drive pad cover onto accessory gearbox. Secure using washers and nuts. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (7)

Using moisture barrier paper, cover inlet and exhaust openings. Cover or plug all engine openings and unattached fittings.

13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 500 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

13. Depreservation of Engine. a.

Comply with all instructions contained in WP 002 00.

b.

If applicable, depreserve lubricating oil supply as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

d.

(1)

Drain engine lubricating tank oil per packager’s manual.

(2)

Remove safety wire and remove drain plug from forward side of accessory gearbox. Discard preformed packing.

(3)

Drain lubricating oil into suitable container.

(4)

Using lubricating oil, lubricate preformed packing.

(5)

Install preformed packing onto drain plug.

(6)

Install drain plug into accessory gearbox. Tighten drain plug to 270-300 lb in. (30.6-33.9 N⋅m) of torque and safety wire.

(7)

Refill engine lubricating tank oil per packager’s manual.

For noninstalled engines: (1)

Remove engine from shipping container per WP 502 00, if applicable.

(2)

Install engine per WP 300 00 or WP 301 00, if applicable.

(3)

Perform paragraph 11, step b.

(4)

Install and start engine per GEK 105054, Chapter 7.

For installed engines: (1)

Remove desiccant from enclosure/package.

(2)

Perform paragraph 11, step b.

(3)

Install and start engine per GEK 105054, Chapter 7.

14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 501 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE PRESERVATION, DEPRESERVATION, AND STORAGE MAINTENANCE (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 4 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 ................... 0 Alphabetical Index Page

Subject Definitions. .......................................................................................................................... Depreservation of Power Turbine....................................................................................... Installed Power Turbine Preservation For Indefinite Period. .......................................... Installed Power Turbine Preservation For 30 Days or Less. ............................................ Installed Power Turbine Preservation For 60 Days or Less. ............................................ Noninstalled Power Turbine Preservation For 30 Days or Less. .....................................

3 4 3 3 3 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 501 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for the preservation, storage, and depreservation of the LM2500+ Model PK gas turbine power turbine. For LM2500+ Model GV gas generator and Model PV gas turbine power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title

For the LM2500+ Model PK gas turbine power turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator-Gas/Turbine Preservation, Depreservation, and Storage Maintenance WP 500 00 Power Turbine Shipping WP 503 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment. None required.

4.

Consumable Material.

5.

Nomenclature

Part No./Specification

Desiccant Lubricating Oil

MIL-P-3464 MIL-L-23699 or MIL-L-7808

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 501 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Definitions. CAUTION ENGINE OR POWER TURBINE SHALL NOT BE STORED IN ANY MANNER THAT ALLOWS ROUTINE EXPOSURE TO OUTSIDE ELEMENTS.

7.

a.

Installed power turbine: A power turbine installed in the enclosure/package, attached to a gas generator, thereby forming a gas turbine assembly. The engine shall be capable of being started and run to idle level with no further connections required. The attached power turbine and/or accessories shall be capable of being rotated. The enclosure/package shall be weather-tight.

b.

Noninstalled power turbine: A power turbine installed in the enclosure/package, with partial or no service connections in place, incapable of being rotated without further maintenance; or a power turbine installed in the shipping container.

Installed Power Turbine Preservation For 30 Days or Less. a.

8.

Installed Power Turbine Preservation For 60 Days or Less. a.

9.

Refer to WP 500 00.

Refer to WP 500 00.

Installed Power Turbine Preservation For Indefinite Period. a.

Refer to WP 500 00.

10. Noninstalled Power Turbine Preservation For 30 Days or Less. a.

If possible, shipping container shall be stored in shaded area, away from direct sunlight, and within limits of normal environment.

b.

Maintain and update power turbine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions and desiccant replacement.

c.

Every 30 days, inspect container humidity indicator for color. Indicator shall appear blue, indicating safe humidity conditions. If indicator appears pink, proceed as follows: (1)

Remove shipping container cover per WP 503 00.

(2)

Replace desiccant.

(3)

Reinstall shipping container cover per WP 503 00.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 501 00 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines At next 30 day inspection, note humidity indicator appearance. If indicator is any color other than blue, proceed as follows: (a) Repeat substeps (1) and (2). (b) Inspect container cover seal per WP 504 00. Replace seal if required. (c) Reinstall shipping container cover per WP 503 00.

11. Depreservation of Power Turbine. a.

Comply with all instructions contained in WP 002 00.

b.

If applicable, depreserve lubricating oil supply as follows: WARNING LUBRICATING OIL, MIL-L-23699, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

d.

(1)

Drain lubricating tank oil per packager’s manual.

(2)

Prepare gas generator per WP 500 00.

(3)

Refill lubricating tank oil per packager’s manual.

For noninstalled power turbines: (1)

Remove power turbine from shipping container per WP 503 00, if applicable.

(2)

Install power turbine assembly per WP 302 00, if applicable.

(3)

Install gas generator assembly per WP 301 00, if applicable.

(4)

Oil wet gas turbine bearings per paragraph 12, step b.(4) of WP 500 00.

(5)

Start gas turbine per GEK 105054, Chapter 7.

For installed power turbines: (1)

Remove desiccant from enclosure/package, if installed.

(2)

Oil wet gas turbine bearings per paragraph 12, step b.(4) of WP 500 00.

(3)

Start gas turbine per GEK 105054, Chapter 7.

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR/GAS TURBINE SHIPPING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 22 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 21 ................. 1 22 Blank ........... 1 Alphabetical Index Subject

Page

Configuration of Inner Frame. ........................................................................................... 17 Engine Installation Into Shipping Container. ................................................................... 17 Engine Removal From Shipping Container. ...................................................................... 3

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1

GEK 105054 Volume II WP 502 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for installing and removing LM2500+ Model GK gas generator and Model PK gas turbine from the LM2500 universal shipping container. For LM2500+ Model GV gas generator and Model PV gas turbines, shipping and handling instructions of the gas generator are per this work package, with shipping and handling of the two stage power turbine provided in GEK 105052, Operation and Maintenance Manual. In addition this work package covers configuring the LM2500 universal shipping container for shipment of either a gas generator or gas turbine.

2.

Reference Material. Number

Title

For LM2500+ Model GK gas generator and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Maintenance Dolly Usage WP 303 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.

5.

2

Support Equipment. Nomenclature

Part No.

Set, Lift Attachment Fixture, Lifting-Gas Generator Fixture, Lifting-Gas Turbine Container, Shipping-LM2500 Universal Lift, Quad Link (6,000 lb [2721 kg] minimum rating) Sling, Nylon (4,000 lb [1814 kg] minimum rating)

1C8017G01 1C8340G01 1C8341G01 106C7156P02 Local Purchase Local Purchase

Consumable Material. Nomenclature

Part No./Specification

Desiccant

MIL-P-3464

Expendable Material. None required.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Engine Removal From Shipping Container. a.

If desired, move shipping container to enclosure, using hoist and lift attachment set, 1C8017. Refer to table 1 for weights and dimensions of shipping container, gas generator, gas turbine, and power turbine. Table 1. Shipping Weights and Dimensions

Item

Weight

Length

Width

Height

Gas Generator/ Gas Turbine Container

12,000 lb (5,443 kg)

220.00 in. (5,588.0 mm)

101.50 in. (2,578.1 mm)

99.25 in. (2,521.0 mm)

Power Turbine Container

2,700 lb (1,225 kg)

-

-

-

Gas Turbine and Container

20,181 lb (9,154 kg)

-

-

-

Gas Turbine

8,181 lb (3,711 kg) without fuel system

214.725 in. (5,454.02 mm)

-

-

Power Turbine

2,830 lb (1,284 kg)

58.8 in. (1,494 mm)

-

-

Gas Generator

4,735 lb (2,148 kg) without fuel system

161.23 in. (4,095.2 mm)

-

-

Gas Turbine (L50101)

8,104 lb (3,676 kg) with forward adapter

191.248 in. (4,857.70 mm)

-

-

Power Turbine (L50101)

3,314 lb (1,503 kg)

-

-

-

Gas Generator (L50101)

4,590 lb (2,082 kg)

137.753 in. (3,498.93 mm)

-

-

Forward Adapter

100 lb (45 kg)

-

-

-

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3

GEK 105054 Volume II WP 502 00 b.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Prepare shipping container as follows: (1)

Depressurize shipping container by depressing button located in center of pressure relief valve (figure 1).

(2)

Loosen nuts on T-bolts that secure shipping container cover to base.

(3)

Rotate T-bolts so boltheads drop into lower flange recess.

(4)

Using quad link lift, attach hoist to lift rings on shipping container cover (Detail A).

(5)

Attach nylon control lines onto shipping container cover. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE THAT ALL FASTENERS ARE IN UNLOCKED POSITION BEFORE LIFTING TOP SECTION OF CONTAINER OR DAMAGE TO CONTAINER AND ENGINE MAY OCCUR. (6)

Using hoist, lift shipping container cover straight up until clear of engine.

(7)

Using nylon control lines and hoist, move shipping container cover clear of engine and shipping container base.

(8)

Lower shipping container cover onto wooden support skids. Remove hoist. Leave quad link lift installed, if desired.

(9)

Lower four shipping container corner alignment posts. NOTE

Remove gas generator per step e. Remove gas turbine per step f. c.

Remove gas generator from shipping container as follows: (1)

4

Attach hoist rated for 10,000 lb (4536 kg) minimum onto lift fixture, 1C8340.

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 502 00

Figure 1. LM2500 Universal Shipping Container, 106C7156P02 (Sheet 1 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. LM2500 Universal Shipping Container, 106C7156P02 (Sheet 2 of 2) 6

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

ESTABLISH AND RECORD CENTER OF GRAVITY OF LIFT FIXTURE TO PREVENT FIXTURE PITCHING UPON REMOVAL FROM GAS GENERATOR. (2)

Remove the top 4 fuel feed tubes to give access to the CRF forward flange bolts and nuts.

(3)

Install lift fixture, 1C8340, aft bracket (figure 2) onto gas generator as follows: CAUTION

SET ASIDE GAS GENERATOR HARDWARE FOR REUSE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (a) Remove bolt and self-locking nut at 12:00 o’clock position of compressor rear frame (CRF) forward flange. (b) Remove seven bolts and self-locking nuts to either side of removed bolt and nut. (c) Install lift fixture, 1C8340, aft bracket onto aft side of CRF forward flange. (d) Using fifteen 0.3125-18 bolts and nuts, attach lift fixture aft bracket onto CRF forward flange. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque. (4)

Raise lift fixture, 1C8340, to working height.

(5)

Adjust lift fixture trolley for proper center of gravity with gas generator installed.

(6)

Position lift fixture, 1C8340, over gas generator.

(7)

Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on compressor front frame (CFF).

(8)

Using two quick-release pins, attach lift fixture aft links to lift fixture aft bracket previously installed on gas generator above.

(9)

Remove forward yoke (figure 3) of shipping container from gas generator as follows: (a) Using lift fixture, 1C8340, and hoist, take up weight of gas generator so that shipping container forward yoke mounting pins can be removed from CFF.

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7

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 2. Gas Generator Lift Fixture, 1C8340 (Sheet 1 of 2) 8

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 502 00

Figure 2. Gas Generator Lift Fixture, 1C8340 (Sheet 2 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. Shipping Container Inner Frame-Gas Generator Configuration 10

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

(b) Remove cotter pins and special flat washers from forward yoke mounting pins. (c) Remove forward yoke mounting pins from CFF. (d) Using nylon sling, attach hoist to forward yoke. (e) Remove eight bolts, washers, and nuts used to secure forward yoke to inner cradle mounting pads. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE FORWARD YOKE IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (f) Lift forward yoke and place away from shipping container. (10) Remove aft strongback of shipping container from gas generator as follows: (a) Remove 46 bolts, nuts, and washers that secure aft strongback to turbine mid frame (TMF) aft flange. (b) Using nylon sling, attach hoist to aft strongback. (c) Remove eight bolts, washers, and nuts used to secure aft strongback to inner cradle mounting pads. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE AFT STRONGBACK IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (d) Lift aft strongback and place away from shipping container.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

11

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (11) Using hoist and lift fixture, 1C8340, lift gas generator from shipping container. NOTE Gas generator can be either installed into maintenance dolly, 1C9372, for moving to enclosure or directly into enclosure. (12) Install gas generator into maintenance dolly, 1C9372, per WP 303 00 or into enclosure per WP 301 00. d.

Remove gas turbine from shipping container as follows: (1)

Attach hoist rated for 14,000 lb (6350 kg) minimum onto lift fixture, 1C8341.

(2)

Install lift fixture, 1C8341 (figure 4), onto gas turbine as follows: NOTE

Use of lift fixture, 1C8341, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C8341, attach packager’s lift fixture per packager’s manual. (a) Ensure forward lifting plate is installed in PLUS lifting position on lift fixture, 1C8341. (b) Attach hoist onto lift fixture, 1C8341, hoist attachment points. (c) Raise lift fixture, 1C8341, and align over gas turbine. (d) Using two quick-release pins, attach lift fixture forward links to gas turbine forward handling mounts on CFF. (e) Using two quick-release pins, attach lift fixture aft links to gas turbine ground handling mounts on TRF.

12

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 502 00

Figure 4. Gas Turbine Lift Fixture, 1C8341 Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

13

GEK 105054 Volume II WP 502 00 (3)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Remove forward yoke (figure 5) of shipping container from gas turbine as follows: (a) Using lift fixture, 1C8341, and hoist, take up weight of gas turbine so that shipping container forward yoke mounting pins can be removed from CFF. (b) Remove cotter pins and special flat washers and remove forward yoke mounting pins from CFF. (c) Using nylon sling, attach hoist to forward yoke. (d) Remove eight bolts, washers, and nuts used to secure forward yoke to inner cradle mounting pads. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE FORWARD YOKE IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (e) Lift forward yoke and place away from shipping container. (4)

Remove aft strongback of shipping container from gas turbine as follows: (a) Remove 46 bolts, nuts, and washers that secure aft strongback to turbine rear frame (TRF) aft flange. (b) Using nylon sling, attach hoist to aft strongback. (c) Remove eight bolts, washers, and nuts used to secure to inner cradle mounting pads.

14

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 5. Shipping Container Inner Frame-Gas Turbine Configuration Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

15

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE AFT STRONGBACK IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (d) Lift aft strongback and place away from shipping container. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (5)

Using hoist and lift fixture, 1C8341, lift gas turbine from shipping container. NOTE

Gas turbine can be either installed into maintenance dolly, 1C9372, for moving to enclosure or directly into enclosure. (6)

16

Install gas turbine into maintenance dolly, 1C9372, per WP 303 00, or into enclosure per WP 300 00.

e.

Remove engine log book from shipping container receptacle.

f.

If required, install shipping container cover onto base as follows: (1)

Install 80-90 lb (36.3-40.8 kg) of desiccant and shipping container hardware into proper receptacles of shipping container.

(2)

Using low power heat gun, renew humidity indicator, if necessary.

(3)

Using quad link lift, attach 4000 lb (1814 kg) hoist to lift rings on shipping container cover (figure 1, detail A).

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. CAUTION BEFORE LOWERING UPPER CONTAINER HALF, ALIGN ALL T-BOLTS IN SLOTS, TO PREVENT COCKING OF LID AND POSSIBLE DAMAGE TO FLANGE GASKET.

7.

(4)

Raise four shipping container corner alignment posts.

(5)

Carefully lift top section of container straight up.

(6)

Using nylon control lines, align top cover with base section and lower.

(7)

Push all T-bolt fasteners up and through slots of upper container and turn 90 degrees (across slots). Hold T-boltheads in position (across slots) with suitable wrench or pliers. Tighten nuts to 35-42 lb ft (47.5-56.9 N⋅m) of torque.

Configuration of Inner Frame. a.

Inspect shipping container per WP 504 00. NOTE Universal shipping container, 106C7156, requires configuring the inner frame for mounting different engines. If same style engine is to be installed into shipping container as was removed, proceed to paragraph 8.

b. 8.

Configure inner frame for gas generator or gas turbine installation per placard located on shipping container.

Engine Installation Into Shipping Container. NOTE Prior to installation of the engine into the shipping container, the fuel system must be drained and purged according to the procedure in WP 300 00 or WP 301 00. a.

If desired, move shipping container to enclosure using hoist and lift attachment set, 1C8017. Refer to table 1 for weights and dimensions of shipping container, gas generator, gas turbine, and power turbine.

b.

If required, prepare shipping container per paragraph 6. step b.

c.

If not previously accomplished, inspect shipping container per WP 504 00. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

17

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

Install gas generator per step d. Install gas turbine per step e. d.

Install gas generator into shipping container as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Using nylon sling and hoist, lift aft strongback and align with proper shipping container inner frame mounting holes. Ensure TMF mounting holes face forward.

(2)

Using eight bolts, nuts, and washers provided, secure aft strongback to inner frame. Tighten nuts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. NOTE

Gas generator can be installed directly into shipping container from enclosure, if desired. (3)

If necessary, prepare maintenance dolly for gas generator removal per WP 303 00. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

18

(4)

Using hoist and lift fixture, 1C8340, lift gas generator.

(5)

Align gas generator TMF with shipping container aft strongback.

(6)

Position TMF aft flange against forward flange of shipping container aft strongback.

(7)

Using 46 bolts, nuts, and washers, secure gas generator TMF to aft strongback. Install boltheads facing forward with washers next to nuts. Tighten bolts to 13-18 lb ft (17.6-24.4 N⋅m) of torque.

(8)

Using nylon sling and hoist, lift forward yoke.

(9)

Carefully position forward yoke over CFF.

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GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (10) Lower forward yoke onto CFF.

(11) Align gas generator CFF mounting brackets with forward yoke mounting holes. (12) Using forward yoke mounting pins and special flat washers, secure gas generator CFF to forward yoke. Slide cotter pins through mounting pins. (13) Using eight bolts, nuts, and washers, secure forward yoke to shipping container inner frame. Tighten bolts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. (14) Remove lift fixture, 1C8340 (figure 2), from gas generator as follows: (a) Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on CFF. (b) Using two quick-release pins, attach lift fixture aft links to aft bracket installed on gas generator. (c) Remove 15 bolts and self-locking nuts that secure CRF forward flange to lift fixture, 1C8340, aft bracket. (d) Remove lift fixture, 1C8340, aft bracket from CRF forward flange. CAUTION INSTALL PRIME GAS GENERATOR HARDWARE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (e) Install 15 prime bolts and nuts though compressor case rear flange. Install three longer bolts in boltholes used to secure sump support bracket. Tighten bolts to 209-231 lb. in. (23.6-26.0 N⋅m) of torque. (f) Reinstall top 4 fuel feed tubes (if removed). e.

Install gas turbine into shipping container as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Using nylon sling and hoist, lift aft strongback and align with proper shipping container inner frame mounting holes. Ensure TMF mounting holes face forward.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

19

GEK 105054 Volume II WP 502 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Using eight bolts, nuts, and washers provided, secure aft strongback to inner frame. Tighten nuts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. NOTE

Gas turbine can be installed directly into shipping container from enclosure if desired. (3)

If necessary, prepare maintenance dolly for gas turbine removal per WP 303 00. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (4)

Using hoist and lift fixture, 1C8341, lift gas turbine.

(5)

Align gas turbine TRF with shipping container aft strongback.

(6)

Position TRF aft flange against forward flange of shipping container aft strongback.

(7)

Using 46 bolts, nuts, and washers, secure gas turbine TRF to aft strongback. Install boltheads facing forward with washers next to nuts. Tighten bolts to 13-18 lb ft (17.6-24.4 N⋅m) of torque.

(8)

Using nylon sling and hoist, lift forward yoke.

(9)

Carefully position forward yoke over CFF.

(10) Lower forward yoke onto CFF. (11) Align gas turbine CFF mounting brackets with forward yoke mounting holes. (12) Using forward yoke mounting pins and special flat washers, secure gas generator CFF to forward yoke. Slide cotter pins through mounting pins. (13) Using eight bolts, nuts and washers, secure forward yoke to shipping container inner frame. Tighten bolts to 82-95 lb ft (111.2-128.8 N⋅m) of torque.

20

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 502 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION DO NOT OVERTIGHTEN SELF-LOCKING NUTS ON CLEVISES, OR DAMAGE TO ENGINE SHALL OCCUR. (14) Remove lift fixture, 1C8341, from gas turbine as follows:

(a) Remove two quick-release pins that attach lift fixture forward links to gas turbine forward handling mounts on CFF. (b) Remove two quick-release pins that attach lift fixture aft links to gas turbine aft handling mounts on TRF. (c) Using enclosure hoist, raise lift fixture, 1C8341, away from gas turbine. f.

Install cover onto shipping container per paragraph 6., step h.

g.

Install logbook into shipping container receptacle.

Change 1

21/(22 Blank)

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

SUBORDINATE WORK PACKAGE

TECHNICAL PROCEDURES AIR RIDE KIT INSTALLATION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE SWP PAGES Total Number of Pages in this SWP is 10 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10.................. 1

Alphabetical Index Subject

Page

Air Ride Kit Installation. .................................................................................................... Air Ride Kit Removal. .........................................................................................................

3 8

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1

GEK 105054 Volume II SWP 502 01 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction.

This work package provides instructions for installing and removing the LM2500 gas turbine shipping container air ride kit. The air ride kit is designed to reduce the possibility of bearing damage in gas generators and gas turbines installed in shipping containers, in areas where trucks and trailers with air ride suspensions may not be available. The air ride kit is made up of two box assemblies. Each assembly is made up of two interconnected air ride boxes. During shipping, one air ride box assembly is attached to each end of the gas turbine shipping container. Each air ride box assembly weighs approximately 850 pounds (386 kg). 2.

Reference Material. None required.

3.

Support Equipment Required.

4.

Nomenclature

Part No.

Kit, Air Ride Container, Shipping-LM2500 Universal

00202050000 106C7156P02

Consumable Material. Nomenclature

Specification

Compressed air 5.

2

Expendable Material. None required.

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GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Air Ride Kit Installation. NOTE

•

Air ride kit can only be installed on containers that have a dark blue painted base (bottom section of container).

•

Two interconnected air ride boxes make up each air ride box assembly.

a.

Open air pressure release valve (9, figure 1), two valves inside each of the four air ride boxes (1 and 15), to release any residual air pressure present in the air bags.

b.

Remove bolts (5) that secure air ride box lids (2) to boxes. Open box lids. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT.

c.

Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity connected to yellow lifting bars (4), move left side air ride box (1) into position at end of gas turbine shipping container (11). Align boltholes in air ride box to boltholes in gas turbine shipping container. NOTE Do not fully tighten bolts until both air ride boxes and connecting channel have been installed with all bolts hand-tight.

d.

Secure left side air box (1) to gas turbine shipping container with 12 bolts (3). Tighten bolts hand-tight.

e.

Repeat steps 6.c. and 6.d. to install right side air box (15) to gas turbine shipping container.

f.

Install connecting channel (13) to air ride boxes (1 and 15), aligning boltholes in connecting channel with boltholes in air ride boxes. Secure connecting channel to each air ride box with four bolts (12). Tighten bolts hand-tight.

g.

Tighten bolts (3) to 69-81 lb ft (94-109 N·m) of torque.

h.

Tighten bolts (12) to 69-81 lb ft (94-109 N·m) of torque.

i.

Repeat steps 6.c. through 6.h. to install second air ride box assembly to other end of gas turbine shipping container. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

3

GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Air Ride Kit (Sheet 1 of 3) 4

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II SWP 502 01

Figure 1. Air Ride Kit (Sheet 2 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5

GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Air Ride Kit (Sheet 3 of 3) 6

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines j.

Verify, and adjust as necessary, that adjustable shock dampers (14, figure 1) are set to the No. 6 setting.

k.

Close lids on the four air ride boxes and secure each lid with two bolts (5). Tighten bolts to 69-81 lb ft (94-109 N·m) of torque.

l.

Open the two air shutoff valves (6) inside each of the four air ride boxes. WARNING SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS.

m. Using compressed air and air pressure gauges (7), apply air to air inlet valves (8) to inflate air bags to 40-50 psig (276-344 kPa gage). NOTE If gas turbine shipping container is to be transported empty, it is acceptable, but not a requirement, to pressurize air bags. n.

After air bags are pressurized to the correct air pressure setting, remove compressed air source and close the two air shutoff valves (6) inside each of the four air ride boxes. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT. NOTE If gas turbine shipping container is lifted with a forklift or overhead crane or hoist, air ride box assemblies may sag off ends of shipping container. This is acceptable and will not damage the air ride box assemblies or container.

o.

Using forklift, or overhead crane or hoist, install gas turbine shipping container on truck trailer bed.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

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GEK 105054 Volume II SWP 502 01

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

DURING TRANSPORT OF GAS TURBINE, MAKE SURE SHIPPING CONTAINER IS NOT DIRECTLY CHAINED TO OR IN DIRECT CONTACT WITH TRAILER BED, OR DAMAGE TO GAS TURBINE BEARINGS MAY RESULT.

7.

p.

Secure air ride boxes on each corner of gas turbine shipping container to truck trailer bed, using chains between trailer and tie down rings (10) on air ride box (figure 2). Make sure clearance between gas turbine shipping container (11) and bed of truck is between 2-3 inches (51-76 mm). Gas turbine shipping container must not be chained to or in direct contact with trailer bed.

q.

If clearance between gas turbine shipping container (11) and bed of truck is not between 2-3 inches (51-76 mm), remove tie-down chains and verify air ride box inflation pressure of 40-50 psig (276-344 kPa gage).

Air Ride Kit Removal. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT. NOTE If gas turbine shipping container is lifted with a forklift or overhead crane, air ride kits may sag off ends of shipping container. This is acceptable and will not damage the kits or container.

8

a.

If necessary, using forklift or overhead crane or hoist, remove gas turbine shipping container from truck trailer bed and place on shop floor or other suitable surface.

b.

Open the two air shutoff valves (6, figure 1) inside each of the four air ride boxes (1 and 15).

c.

Open two air pressure release valves (9) inside each of the four air ride boxes, to release air pressure present in the air bag.

d.

Remove bolts (12) that secure connecting channel (13) to left and right air ride boxes (1 and 15). Remove connecting channel.

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II SWP 502 01

Figure 2. Tie-Down of Air Ride Box to Truck Trailer Bed Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9

GEK 105054 Volume II SWP 502 01

10

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

e.

Remove bolts (5) that secure air ride box lids (2) to air ride boxes. Open box lids.

f.

Remove bolts (3) that secure air ride boxes to gas turbine shipping container (11).

g.

Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity connected to yellow lifting bars (4), remove each air ride box from gas turbine shipping container (11).

Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE SHIPPING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 14 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 13 ................. 0 14 Blank ........... 0 Alphabetical Index Subject

Page

Power Turbine Installation into Shipping Container. ...................................................... 11 Power Turbine Removal from Shipping Container. .......................................................... 3

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides instructions for installing and removing LM2500+ Model PK gas turbine power turbine into a shipping container. For Model GV gas generator and Model PV gas turbine power turbines, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title

For LM2500+ Model PK gas turbine power turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Power Turbine Forward Adapter Replacement WP 220 00 Power Turbine Assembly Replacement WP 302 00 Maintenance Dolly Usage WP 303 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine power turbines: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.

5.

Support Equipment. Nomenclature

Part No.

Fixture, Lifting-Power Turbine Mount Set, Ground Handling-Power Turbine Fixture, Aft Lift and Turn-Power Turbine Frame Assembly, Maintenance Dolly Container, Shipping-Power Turbine Lift, Quad Link (6,000 lb [2,721 kg] minimum rating) Sling, Nylon (4,000 lb [1,814 kg] minimum rating) Gun, Heat

1C6955G03 1C8321G01 1C8342G01 1C9372G04 106C7157P01 Local Purchase Local Purchase Local Purchase

Consumable Material. Nomenclature

Part No./Specification

Desiccant Thread Lubricant

MIL-P-3464 GE Spec A50TF201

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Power Turbine Removal from Shipping Container. a.

Comply with all instructions contained in WP 002 00. NOTE Shipping container with power turbine installed weighs approximately 5,800 lbs (2,630 kg).

b.

If desired, move shipping container, 106C7157, to enclosure per one of following methods: (1)

Using hoist and sling, proceed as follows: (a) Attach quad link lift to four lifteyes on shipping container lid. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (b) Using hoist attached to quad link lift, lift and move shipping container and power turbine to enclosure site. (2)

Using forklift, proceed as follows: (a) Align lift forks with guide tubes in base of shipping container. (b) Lift and move shipping container to enclosure site.

c.

Prepare shipping container as follows: (1)

Depressurize shipping container by depressing button located in center of pressure relief valve (figure 1).

(2)

Loosen nuts on 40 T-bolts that secure shipping container cover to base.

(3)

Rotate T-bolts so boltheads drop into lower flange recess.

(4)

Using quad link lift, attach hoist to lift rings on shipping container cover. Attach nylon control lines onto shipping container lift rings.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Power Turbine Shipping Container (Sheet 1 of 3) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 503 00

Figure 1. Power Turbine Shipping Container (Sheet 2 of 3) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 1. Power Turbine Shipping Container (Sheet 3 of 3) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE THAT ALL FASTENERS ARE IN UNLOCKED POSITION BEFORE LIFTING CONTAINER COVER, OR SHIPPING CONTAINER SHALL BE DAMAGED. (5)

Using hoist, lift shipping container cover straight up until clear of power turbine.

(6)

Using nylon control lines and hoist, move shipping container cover clear of power turbine and shipping container base.

(7)

Lower shipping container cover onto wooden support skids. Remove hoist. Leave quad link lift installed, if desired.

(8)

Lower four shipping container corner alignment posts. NOTE

d.

•

There are two methods for removal of power turbine from shipping container. For use of lift fixture, 1C6955, refer to step (1). For use of aft lift and turn fixture, 1C8342, and shipping container forward strongback, refer to step (2).

•

Use of lift fixture, 1C6955, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C6955, attach packager’s lift fixture per packager’s manual.

•

Aft lift and turn fixture, 1C8342, cannot be used when installing power turbine into enclosure.

Remove power turbine from shipping container as follows: (1)

Install lift fixture, 1C6955, onto power turbine as follows: (a) Install power turbine ground handling mount fixtures, 1C8321, onto power turbine as follows: CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING REMOVAL, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. 1

Remove nine bolts, in boltholes 1 through 9, on horizontal split flange of power turbine stator case. Retain engine hardware for reinstallation.

7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

Ground handling mount fixtures, 1C8321, are marked as to which side of power turbine they are to be installed on. Ensure fixtures are installed onto lower side of horizontal split line flange. 2

Using slave hardware, attach ground handling mount fixture, 1C8321, onto power turbine. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque.

(b) Install lift fixture, 1C6955 (figure 2), onto power turbine as follows: 1

Attach hoist, rated at 6,000 lb (2,721 kg) minimum, to lift fixture, 1C6955, by engaging hoist hook in trolley clevis of lift fixture.

2

Position lift fixture, 1C6955, over power turbine assembly.

3

Lower lift fixture, 1C6955, until lift pins in legs of forward yoke align with forward holes in ground handling mount fixtures, 1C8321, on power turbine.

Figure 2. Lift Fixture, 1C6955

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 4

Raise latch and slide lift pin into ground handling mount fixture, 1C8321, on both sides of power turbine.

5

Ensure spring stop returns latch to down position to retain pin in engaged position.

6

Using ball lock pins, attach aft brackets to ground handling mounts of turbine rear frame (TRF).

(c) Remove eight capscrews, washers, and nuts that secure shipping container forward strongback cross bar to inner frame. (d) Remove three cotter pins and washers from the three dowel pins and remove three mounting pins that attach TRF handling mounts to inner frame. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (e) Using hoist and lift fixture, 1C6955, lift power turbine from shipping container. Install into maintenance dolly, 1C9372, per WP 303 00, or into enclosure per WP 302 00. (2)

Install aft lift and turn fixture, 1C8342, onto power turbine as follows: NOTE

Aft lift and turn fixture, 1C8342, cannot be used with power turbine forward adapter installed on power turbine. (a) If installed, remove power turbine forward adapter per WP 220 00. (b) Using hoist, raise aft lift and turn fixture, 1C8342 (figure 3), and align behind TRF. (c) Using 32 capscrews, washers, and nuts, attach aft lift and turn fixture, 1C8342, to TRF aft flange. Tighten capscrews to 40-60 lb in. (4.6-6.7 N⋅m) of torque. (d) Install hoist and nylon sling onto shipping container forward strongback. (e) Remove eight bolts, washers, and nuts that secure shipping container forward strongback cross bar to inner frame. (f) Remove three cotter pins and washers from the three dowel pins and remove three mounting pins that attach TRF handling mounts to inner frame.

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. Aft Lift and Turn Fixture, 1C8342 WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (g) Using hoist(s) and aft lift and turn fixture, 1C8342, lift power turbine from shipping container. Install into maintenance dolly, 1C9372, per WP 303 00. e.

If required, install shipping container cover onto base as follows: (1)

Install 80 lbs (36.3 kg) of desiccant and shipping container hardware into proper receptacles of shipping container.

(2)

Using low power heat gun, renew humidity indicator, if necessary.

(3)

Using quad link lift, attach hoist to lift rings on shipping container cover.

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. CAUTION BEFORE LOWERING UPPER CONTAINER HALF, ALIGN ALL T-BOLTS IN SLOTS, TO PREVENT COCKING OF LID AND POSSIBLE DAMAGE TO FLANGE GASKET. (4)

Raise four shipping container corner alignment posts.

(5)

Carefully lift top section of container straight up.

(6)

Using nylon control lines, align top cover with base section and lower. CAUTION

ENSURE ALL T-BOLT FASTENERS ARE PROPERLY ENGAGED AND TIGHTENED BEFORE MOVING CONTAINER, OR SHIPPING CONTAINER SHALL BE DAMAGED. (7)

7.

Push all T-bolt fasteners up and through slots of upper container and turn 90 degrees (across slots). Hold T-boltheads in position (across slots) with suitable wrench or pliers. Tighten nuts to 35-43 lb ft (47.5-58.3 N·m) of torque.

Power Turbine Installation into Shipping Container. a.

Inspect shipping container per WP 504 00.

b.

If desired, move shipping container, 106C7157, to enclosure site per paragraph 6., step b.

c.

If installed, remove shipping container cover per paragraph 6., step c.

d.

Align power turbine over shipping container inner frame.

e.

If required, lower four shipping container corner alignment posts.

11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00 f.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Install power turbine into shipping container as follows: WARNING WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY.

g.

(1)

Using hoist(s) and lift fixture, 1C6955, lower power turbine into shipping container.

(2)

Engage three inner frame mounting pins into TRF handling mounts. Secure mounting pins to TRF mounts using three dowel pins, washers, and cotter pins.

(3)

Align bolthole in shipping container forward strongback with boltholes in inner frame.

(4)

Using eight capscrews, washers, and nuts, secure shipping forward strongback to inner frame. Tighten bolts to 480-570 lb in. (54.3-64.4 N⋅m) of torque.

Remove lift fixture from power turbine as follows: NOTE If lift fixture, 1C6955, is used, install into shipping container per substep (1). If aft lift and turn fixture, 1C8342, is used, install into shipping container per substep (2). (1)

Remove lift fixture, 1C6955 (figure 2), from power turbine as follows: (a) Remove mounting pins that secure power turbine lift fixture, 1C6955, aft mounting brackets to TRF ground handling mounts. (b) Raise latch and move lift pin to disengage from ground handling fixtures, 1C8321, on both sides of power turbine. (c) Ensure spring stop returns latch to down position to retain pin in disengaged position. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (d) Using hoist, lift and remove lift fixture, 1C6955, from power turbine.

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 503 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (2)

Remove aft lift and turn fixture, 1C8342 (figure 3), from power turbine as follows: (a) Remove 32 bolts, washers, and nuts that secure aft lift and turn fixture, 1C8342, to TRF aft flange. (b) Lift aft lift and turn fixture, 1C8342, away from power turbine.

h.

If installed, remove ground handling mount fixtures, 1C8321, from power turbine as follows: (1)

Remove five slave bolts, in boltholes 3 through 5 and 7 and 8, on horizontal split flange of power turbine stator case.

(2)

Lightly coat engine hardware threads and contact faces with thread lubricant. CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING INSTALLATION, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. (3) i.

Reinstall bolts into power turbine stator case horizontal split flange. Tighten bolts to 162-178 lb in. (18.4-20.1 N⋅m) of torque.

Prepare shipping container for shipment or storage per paragraph 6., step e.

13/(14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

WORK PACKAGE

TECHNICAL PROCEDURES SHIPPING CONTAINER INSPECTION AND RECONDITIONING (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 20 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 19 ................. 0 20 Blank ........... 0 Alphabetical Index Page

Subject Shipping Container Inspection........................................................................................... Shipping Container Reconditioning Procedures................................................................

3 4

1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00 1.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Introduction. This work package provides inspection and reconditioning procedures for LM2500+ universal shipping containers and LM2500+ power turbine shipping containers.

2.

Reference Material. None required.

3.

Support Equipment. None required

4.

Consumable Material.

5.

Nomenclature

Part No./Specification

Desiccant Bags Chromate Free Primer Paint Epoxy Polymide Topcoat Paint Gasket Material Isopropyl Alcohol Mastic Sealant Soap Solution Thread Lubricant

MIL-D-3464 MIL-P-2444/1 MIL-C-22750 MIL-R-6855, CL-II Fed Spec TT-I-735 MIL-S-8802 Local Purchase GE Spec A50TF201 or MIL-T-5544

Expendable Material. None required.

2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Shipping Container Inspection. a.

Inspect LM2500+ universal shipping containers as follows: NOTE Pay particular attention to suspension system bolts during this inspection. Shipping containers shall be inspected per following criteria prior to repair or reuse. (1)

Inspect T-bolt fasteners, nuts, and shipping container T-bolt slots for cracks, burrs, elongation, misalignment, defective threads, and other mechanical defects affecting serviceability.

(2)

Inspect braces, lifting rings, eyes, lugs, roller rings, relief valves, desiccant holders, access plate gaskets, record receptacles, and assembly guides for cracks, ruptures, deterioration, misalignment, and other defects.

(3)

Inspect closure flanges for cracks, dents, misalignment, and other defects that would affect sealing of shipping container.

(4)

Inspect closure flange gasket for permanent deformation, cuts, abrasions, or other surface defects that would affect sealing of shipping container.

(5)

Inspect shipping container top and bottom shell for dents, cracks, gouges, corrosion damage, holes, or ruptures in surface that would affect serviceability. Scratches or gouges not more than 0.062 inch (1.57 mm) deep and dents not more than 0.50 inch (12.7 mm) are acceptable without repair.

(6)

Inspect skids for broken ends, splits, dry rot, and other defects that would affect serviceability. Lengthwise splits not exceeding 2.0 feet (0.6 m) in length and 0.50 inch (12.7 mm) wide are acceptable without replacement.

(7)

Inspect shipping container shock mounts for cracks, tears, bond separation, splits, and other defects that would affect serviceability.

(8)

Use procedure outlined in paragraph 7, step d. to check pressure relief valve for proper operation.

(9)

Shipping containers reconditioned for use shall be checked for overall leakage prior to time gas generator/turbine is preserved. If shipping container is reconditioned for use and not used, pressurize and check for leaks. Use method listed in paragraph 7, step d.

3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

(10) Inspect inner frame aft support ring and forward shipping yoke mounting pads for cracking, burrs, hole elongation, and other mechanical defects affecting serviceability. Inspect fuel manifold support brackets and vertical posts for mechanical damage. (11) Inspect forward shipping yoke and aft mounting ring for cracking, burrs, hole elongation, and other mechanical damage affecting serviceability. Inspect bolts, washers, and nuts used with aft mounting ring for thread damage. Inspect mounting pins and retainers used with forward shipping yoke for cracking, wear, or other mechanical defects. (12) Inspect shipping container finish. Refer to paragraph 7, step h. for finish requirements. Refer to paragraph 7, step j. for stenciling requirements. b.

7.

Inspect LM2500+ power turbine shipping containers per steps a.(1) through (9) and as follows: (1)

Inspect forward strongback and inner frame mounting pads for cracking, burrs, hole elongation, and other mechanical defects affecting serviceability.

(2)

Inspect forward strongback, inner frame, and mounting pins for cracking, burrs, hole elongation, and other mechanical damage affecting serviceability. Inspect bolts, washers, and nuts used with forward strongback and inner frame for thread damage. Inspect mounting pins and retainers used with inner frame for cracking, wear, or other mechanical defects.

(3)

Inspect shipping container finish. Refer to paragraph 7, step h. for finish requirements. Refer to paragraph 7, step j. for stenciling requirements.

Shipping Container Reconditioning Procedures. NOTE Reusable metal shipping containers for gas generator, gas turbines, and power turbines shall not be used for purposes other than storage and shipment of gas generators, gas turbines, and power turbines. Reusable metal shipping containers are high cost items procured and used for storage and shipment of gas generators, gas turbines, and power turbines. Strict inventory control is maintained to ensure their availability for all serviceable gas generators, gas turbines, or power turbines placed into supply system. Use of metal shipping containers is mandatory for all gas generators, gas turbines, or power turbines subject to indefinite storage and shipment. a.

Shipping containers that need minor repairs shall be reconditioned, only as necessary, to place shipping container into serviceable condition. It is unnecessary to obtain like-new appearance. Metal surfaces shall be painted per step h. of this paragraph.

4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

CLEANING SHALL BE PERFORMED IN A CLEAN, WELL-VENTILATED AREA. PROTECTIVE CLOTHING AND GLOVES SHALL BE WORN. EXTINGUISHERS SHALL BE AVAILABLE IN CASE OF FIRE. b.

Shipping containers shall be cleaned as part of reconditioning. Any applicable procedures that follow shall be observed: (1)

Clean shipping container interior to remove fuel and oil, rags, bolts and nuts, desiccant bags, and other debris. WARNING STEAM-CLEANING CAN CAUSE SERIOUS BURNS. WEAR PROTECTIVE GLOVES, APRON, AND FACE SHIELD DURING STEAM-CLEANING PROCESS. SOLVENT IS FLAMMABLE AND IRRITATING TO THE SKIN, EYES, AND RESPIRATORY TRACT. USE GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING AS NECESSARY. USE IN WELL-VENTILATED AREA OR AN APPROVED CLEANING CABINET. KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME.

(2)

Solvent spray or steam-clean shipping containers that require rust removal and refinishing in order to ensure clean and workable surface. WARNING

BLASTING OPERATIONS CAN PRODUCE AIRBORNE PARTICLES THAT ARE HARMFUL TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. (3)

Thorough sandblasting shall be required for shipping containers that need complete internal or external refinishing. CAUTION

USE CARE TO AVOID DIRECT APPLICATION OF STEAM JET TO RUBBER PORTIONS OF SHOCK MOUNTS, OR MOUNTS MAY BE DAMAGED. (4)

Prior to steam-cleaning, remove relief valves, closure flange gaskets, and other parts that may be damaged by steam-cleaning methods. It is not necessary to remove shock mounts, but care shall be taken against direct application of steam jet against rubber portions of mounts.

5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00 (5)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Remove loose and excessive rust from shipping container internal and external surfaces including inner frame, desiccant baskets, attaching hardware, and closure flange gasket surfaces. Use wire brush or sandblasting. Bolts, mounts, and other fasteners that are excessively corroded should be removed for replacement or chemical cleaning and plating as desired. CAUTION

COVER OBSERVATION PORT AND/OR PRESSURE VALVE OPENINGS DURING RUST REMOVAL OR CLEANING OPERATIONS.

c.

(6)

During rust removal or cleaning operations, in vicinity of installed inspection windows or pressure valves, cover openings to prevent damage or contamination.

(7)

Remove all mounting hardware, rubber shock mounts, nuts, bolts, valves, skids, etc., that have been selected for replacement during inspection specified in paragraph 6.

(8)

Set aside relief valves for inspection and test in accordance with step d. below.

Shipping container surfaces shall be reworked as needed as part of reconditioning. Any applicable procedures that follow shall be observed: WARNING WELDING OPERATIONS SHALL BE PERFORMED BY EXPERIENCED AND TRAINED PERSONNEL. APPROVED SAFETY PROCEDURES AND PROTECTIVE EQUIPMENT SHALL BE USED. CAUTION DO NOT ATTEMPT TO WELD SHIPPING CONTAINERS WHEN PRESSURIZED. (1)

Weld repair cracks, tears, ruptures, or holes in shipping container shell that shall affect serviceability.

(2)

Repair gouges and scratches beyond 0.062 inch (1.57 mm) deep and dents not more than 0.50 inch (12.7 mm) deep by fill-welding.

6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

WEAR PROTECTIVE GLOVES TO PREVENT INJURY FROM SHARP EDGES AND ROUGH SURFACES. (3)

Repair holes and ruptures in shipping container shell by hot forming or straightening any irregularities around damaged area and welding on suitable patch (figure 1). Fabricate patches from 10 or 11 gage hot rolled steel. Extend edges of patch at least 0.50 inch (12.7 mm) in all directions beyond damaged area. All patches are to be installed onto outside of shipping container only. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (4)

Straighten dented or deformed closure flanges by means of hot forming.

Figure 1. Patch Repair of Shipping Container Shell - Typical 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

PARTICLES FROM GRINDING OPERATIONS CAN DAMAGE EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY TRACT PROTECTION IS REQUIRED. (5)

Repair any defects in closure flanges such as scratches, gouges, nicks, or rust pits, that would interfere with effectiveness of seal by fill-welding and flush grinding. Use suitable gages to check for flushness of repaired area. Scattered pits not exceeding 0.062 inch (1.57 mm) in depth do not require fill-welding but do require use of wire brush loose for rust removal.

(6)

Restore mismatched upper and lower shipping container halves to service as follows: (a) Install top cover onto shipping container. (b) Align greatest possible number of attaching holes with installation T-bolt fasteners. (c) Repair misaligned holes whenever possible by elongating hole to maximum of 0.250 inch (6.35 mm). Maintain minimum of 0.250 inch (6.35 mm) distance from outer edge of hole to outer edge of flange. (d) Holes that cannot be aligned by elongating should be fill-welded, ground flush, redrilled, and re-formed. NOTE

Mating surface flange and groove areas require refinishing with at least two coats of chromate free primer paint, prior to installation of seal. (7)

Repair gussets, bumper guards, braces, lifting rings, rollover rings, etc., by straightening, as necessary, and welding any cracks or breaks. All shipping containers that have weld repairs accomplished shall be carefully checked for leaks in weld area at time of pressurization. CAUTION

DO NOT ATTEMPT TO WELD SHIPPING CONTAINERS WHEN PRESSURIZED. d.

Relief valves shall be checked for proper type of valve, release pressure, and for leakage following resetting. Relief valves shall release at 0.5-1.5 psig (3.45-10.34 kPa). Apply soap solution. Relief valves shall be bubble free at 0.5 psig (3.45 kPa). Inspect and recondition valves as follows: (1)

Replace preformed packing seats in valve, as necessary, to accomplish sealing.

8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

e.

f.

(2)

Use threading taps or rotary wire brushing to remove excessive thread rust in relief valve receptacles.

(3)

If relief valve threaded openings are oversized, retap openings and install standard pipe bushing of appropriate size.

(4)

When reinstalling relief valves, coat threads with thread lubricant.

Inspection and reconditioning of wooden skids shall follow these general rules: (1)

Inspect skids for deterioration, damage, or loose bolts.

(2)

Wood used for skid refurbishment shall be pretreated.

(3)

Check skids or wood intended for skid replacement for freedom from defects. Small knots are allowed. Knots that have diameter greater than 1/4 width of board are to be avoided.

Removal of water traps shall be accomplished as follows: WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA.

g.

(1)

Any cavities, such as gussets, weld joints, deep rust pits, and dents that shall form water traps when shipping container is in its normal storage position, shall be filled with suitable mastic sealant per MIL-S-8802.

(2)

Voids shall be caulked with sealer after welding and before painting.

Inspect, clean, and recondition gaskets as follows: NOTE Replacement gaskets may be fabricated locally. All joints shall be vulcanized to form continuous gaskets. (1)

Replace any flange gaskets with cuts, abrasions, or other surface defects that would affect sealing of shipping container.

9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (2)

To ensure proper sealing of gaskets, clean all gasket sealing surfaces with isopropyl alcohol. WARNING

PAINTS, PRIMERS, AND THINNERS ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. USE IN A WELL-VENTILATED AREA. FOR SPRAY APPLICATIONS, RESPIRATORY PROTECTION IS ALSO REQUIRED. CAUTION AFTER PAINTING ANY SURFACES OF SHIPPING CONTAINER, ALLOW PAINT TO CURE (DRY) FOR 48 HOURS MINIMUM PRIOR TO CONTAINER USAGE. h.

Surface refinishing of shipping containers shall be accomplished as follows: NOTE All surfaces shall be thoroughly cleaned inside and outside, and all debris removed before application of any finish coatings. (1)

Ensure surfaces are ready for paint application. If any questionable areas are observed, clean areas per paragraph 7, step b.

(2)

At least 25 percent of total area may be bare of paint before complete refinishing is necessary.

(3)

Whenever possible, original paint tones shall be used for touch up paint. Matching of colors is not necessary. NOTE

Use of special purpose paint colors such as red or yellow shall be avoided. (4)

When completely refinishing any painted surface, paint area as follows: (a) Apply one coat of chromate free primer paint. (b) Apply one coat of topcoat paint to match surrounding color.

10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

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GEK 105054 Volume II WP 504 00

(5)

Interior touchup shall consist of mist coat of chromate free primer paint, followed by wet coat of same material.

(6)

When complete interior finish is necessary, second coat of chromate free primer paint shall be continuous and without gross runs or sags. As an alternate, two coats of chromate free primer paint followed by finish coat of topcoat paint of any suitable color shall be acceptable.

(7)

Exterior touchup shall include coat of chromate free primer and coat of topcoat paint.

(8)

Complete exterior finishing shall consist of two coats of chromate free primer and at least one coat of appropriate topcoat paint. Painting shall include closure flange, mating surfaces, and grooved areas that come into contact with closure seals.

The LM2500 universal shipping container stencils shall be placed per approximate locations shown. Stencils shall be applied or renewed onto shipping container as follows: (1)

All sides of shipping container (figures 2 and 3), use 1.00 inch (25.4 mm) characters. CAUTION: RELEASE PRESSURE BEFORE OPENING CONTAINER

(2)

Record receptacle end of shipping container (figure 2) per the following: (a) Use 0.50 inch (12.7 mm) characters: CAUTION: FOR AIRFLOAT TIEDOWN OR TOWING EMPTY CONTAINER ONLY DESICCANT RECEPTACLES AND PRESSURE RELIEF VALVE HUMIDITY INDICATOR OBSERVATION PORT (b) Use 1.00 inch (25.4 mm) characters: RECORDS

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GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Use 2.00 inch (50.8 mm) characters: MGW TARE NET CUBE WIDTH HEIGHT LENGTH (d) Solid black paint to area 10 by 24.25 inches (25.4 by 61.6 cm).

(3)

For top of shipping container (figure 2, detail A) per the following: (a) Use 4.00 inch (101.6 mm) characters: WARNING (b) Use 2.00 inch (50.8 mm) characters: FOR COVER LIFT ONLY

(4)

For sides of shipping container (figure 3) per following: (a) Use 1.00 inch (25.4 mm) characters: SHIP ON AIR RIDE EQUIPPED TRAILERS ONLY LIFT HERE SET/LIFT LUG TIE DOWN (b) Use 2.00 inch (50.8 mm) characters: LM2500 (c) Use 4.00 inch (101.6 mm) characters: DO NOT DROP (d) Use 1.00 by 5.00 inch (25.4 by 127.0 mm) arrows.

(5)

For inner frame of shipping container (figure 4) per following: (a) Use 1.00 inch (25.4 mm) characters: GT GG GG PLUS GT PLUS

12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 504 00

Figure 2. Universal Shipping Container-End View 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 3. Universal Shipping Container-Side View 14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 504 00

Figure 4. Universal Shipping Container-Inner Frame 15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00 j.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

The LM2500 power turbine shipping container stencils shall be placed per approximate locations shown. Stencils shall be applied or renewed onto shipping container as follows: (1)

For all sides of shipping container (figures 5 and 6) in 1.00 inch (25.4 mm) characters use: CAUTION: RELEASE PRESSURE BEFORE OPENING CONTAINER

(2)

Record receptacle end of shipping container (figure 5) per following: (a) Use 0.50 inch (12.7 mm) characters: DESICCANT RECEPTACLES AND PRESSURE RELIEF VALVE HUMIDITY INDICATOR OBSERVATION PORT (b) Use 1.00 inch (25.4 mm) characters: RECORDS (c) Use 2.00 inch (50.8 mm) characters: MGW TARE NET CUBE WIDTH HEIGHT LENGTH

(3)

For top side of shipping container (figure 6) per following: (a) Use 2.00 inch (50.8 mm) characters: WARNING (b) Use 2.00 inch (50.8 mm) characters: FOR COVER LIFT ONLY

(4)

For lower sides of shipping container (figure 6) per following: (a) Use 1.00 inch (25.4 mm) characters: SHIP ON AIR RIDE EQUIPPED TRAILERS ONLY

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LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 504 00

(b) Use 2.00 inch (50.8 mm) characters: LM2500 LPT (c) Use 4.00 inch (101.6 mm) characters: DO NOT DROP (5)

For base sides of shipping container (figure 6) per following: (a) Use 1.00 inch (25.4 mm) characters: LIFT HERE TIE DOWN (b) Use 1.00 by 5.00 inch (25.4 by 127.0 mm) arrows.

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GEK 105054 Volume II WP 504 00

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

Figure 5. Power Turbine Shipping Container-End View 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume II WP 504 00

Figure 6. Power Turbine Shipping Container-Side View 19/(20 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

Gek105054 LM2500 Plus O&M Manual

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