SBLM2500 IND 178rev1
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ROUTINE GE Industrial AeroDerivative Gas Turbines
SERVICE BULLETIN
LM2500-IND-0178 Revision 1 January 19, 2004
GE PROPRIETARY INFORMATION
Th The e inf infor orma matio tion n co cont ntain ained ed in thi this s docu documen mentt is GE pr prop oprie rieta tary ry inf infor ormat matio ion n and and is discl disclose osed d in co conf nfide idence nce.. It is the prop proper erty ty of GE and and sh shal alll not not be used, used, dis disclo closed sed to ot other hers, s, or reprod reproduc uced ed 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, designs, desi gns, or configur configurati ation on changes changes or to obtain obtain FAA FAA or any governme government nt or regulato regulatory ry approval approval to do so. If conse consent nt is given given for for repro reprodu ducti ction on in whole whole or in part, part, thi this s notic notice e and and the notice 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. Copyright (2004) General Electric Company, U.S.A. SUBJECT: 9th Stage Air Line Bracket Change TRANSMITTAL TRANSMITT AL INFORMATION INFORMATION LM2500-IND-0178, SERVICE BULLETIN REVISION 1 This section transmits Revision 1 to LM2500-IND-0178, dated 19 January 2004. The purpose of this revision is to revise: (1) Paragrap Paragraph h I.D. Complia Compliance nce Remove Service Bulletin LM2500-IND-0178, dated 17 November 2003, in its entirety, and replace with Service Bulletin LM2500-IND-0178, Revision 1, dated 19 January 2004. The revision bars in the left margin indicate actual text changes. Revision bars are not used to indicate format and sequence changes. This Service Bulletin is reissued in its entirety.
ROUTINE
PAGE 1 of 18
LM2500-IND-0178 Revision 1 January 19, 2004
I. PLANNING INFORMATION INFORMATION A. Effectivity (1) PRODUCTS: LM2500+ LM2500+ DLE DLE Mo Models dels (2) ENGINE SERIAL NUMBERS: LM2500+ DLE gas generators, serial numbers 636-050, 636-051, 636-101 through 636-106, 636-108, 642-101 through 642-147, 642-149 through 642-152, are affected by this Service Bulletin. LM2500+ DLE gas turbines, serial numbers 559-051, 559-052, 559-101 through 559-116, are affected by this Service Bulletin. B. Reason (1) Objective: This Service Bulletin introduces new 9th stage low pressure turbine (LPT) cooling support brackets, and improved LPT cooling air manifolds. (2) Condition/Event(s): From the field there is evidence of cracking on some 9th stage LPT cooling air manifolds and manifold brackets. (3) Cause: The cracking is believed to be caused by high resonant stress in the 9th stage air manifold and manifold bracket. (4) Improvement: This change reduces the potential for 9th stage air manifold and manifold bracket cracking, by the introduction of improved 9th stage LPT cooling support brackets with increased material thickness along with changes in bracket location C. Description This Service Bulletin provides instructions to replace existing LPT cooling air manifolds and manifold brackets with new design parts. D. Compliance Category: Routine (R)
Level: Field (F)
Timing Code: 6
GE recommends compliance with this Service Bulletin at component part repair or replace replacement. ment. PAGE 2 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
E. Manpower Approximately 4 man-hours are required to accomplish this Service Bulletin F. Tooling Special tooling is not required. G. Material Requirements (1) The followi following ng materials materials are required required to accomplish this this Service Bulle Bulletin: tin: Part Num ber
Nomenclature
Quantity
9134M 25P33
Strap
(1)
AS3237-07
Bolt, Machine
(4)
J646P19D
Bolt, Machine
(2)
L42912G01
Manifold, Air-LPT
(1)
L42913G01 L51392G01
Manifold, Air-LPT Cooling Bracket, Support-LPT Cooling
(1) (1)
L51393G01
Bracket, Support-LPT Cooling
(1)
L51396G01
Bracket, Support-LPT Cooling
(1)
L51397G01
Bracket, Support-LPT Cooling
(1)
L51408G01
Bracket, LPT Cooling
( 1)
L51409P01
Bracket, LPT Cooling
( 1)
9608M 08G52
Gasket
( 2)
9608M 08G53
Gasket
( 2)
9608M 08G55
Gasket
( 1)
The cost and delivery for this material will be quoted upon request or upon receipt of purchase order submitted to the address on the next page:
PAGE 3 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
GE Marine and Industrial AeroDerivative Gas Turbines Mail Drop S-133 One Neumann Way PO Box 156301 Cincinnati, OH 45215-6301 U.S.A. Attn: GE Customer Account Manager Fax: (513) 552-5008 following ng consumable materials, materials, which shoul should d be available locally locally,, are (2) The followi required to accomplish this Service Bulletin: Part Num ber
Nomenclature
Quantity
GP460 (GE Spec A50TF201) or
Thread Lubricant
( A R)
736L680G01
Safety Cable
( A R)
R297P02 (ALT)
Safety W ire
( A R)
MIL-T-5544
H. Materi Material al Configura Configuration tion Chart Ol Old d Part Numbe mber
Nomen menclature
Qt Qty y
Ac Acttion
New New Part Number
Qty
682L572G06
Kit, Fuel System
( 1)
RW
682L572G08
(1)
.J646P17D
Bolt, Machine
( 120)
Q TC
.J646P17D
(118)
----------
Bolt, Machine
( -)
AD
.J646P19D
(2)
----------
Bracket, LPT Cooling
( -)
AD
.L51409P01
(1)
L50001G02
Assembly, Gas Gas Generator
( 1)
RW
L50001G04
(1)
.L51 .L5126 264G 4G01 01
Mani Manifo folld, Ai Airr LPT LPT Cooling
( 1)
RE
.L42913G01
(1)
.L51265G01
Manifold, Air LPT
( 1)
RE
.L42912G01
(1)
.L51 .L5124 242G 2G01 01
Br Bra ack cke et, Supp Suppor ortt LPT Cooling
( 1)
RE
.L51392G01
(1)
PAGE 4 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
Ol Old d Part Numbe mber
Nomen menclature
Qt Qty y
Ac Acttion
New New Part Number
Qty
.L51267G01
Bra rac cket, Support-LPT Cooling
( 1)
RE
.L51393G01
(1)
.L51 .L5122 220G 0G01 01
Br Bra ack cke et, Supp Suppor ortt LPT Cooling
( 1)
RE
.L51397G01
(1)
----------
Bracket, LPT Cooling
( -)
AD
.L51408G01
(1)
----------
Bolt, Machine
( -)
AD
.AS3237-07
(4)
----------
Strap
( -)
AD
.9134M25P125
(1)
Strap
( 3)
Q TC
.9134M25P125
(1)
Strap
( -)
AD
.9134M25P125
(1)
Strap
(3)
Q TC
.9134M25P33
(1)
.9134M25P125 ----------
.9134M25P33 ----------
Strap
( -)
AD
.9134M25P33
(1)
-------------------
Strap
( -)
AD
.9134M25P33
(1)
Strap
( -)
AD
.9134M25P33
(1)
L50001G01
Assembly, Gas Gas Generator
( 1)
RW
L50001G05
(1)
.L51 .L5126 264G 4G01 01
Mani Manifo folld, Ai Airr LPT LPT Cooling
( 1)
RE
.L42913G01
(1)
.L51265G01
Manifold, Air-LPT
(1)
RE
.L42912G01
(1)
.L51 .L5124 242G 2G01 01
Br Bra ack cke et, Supp Suppor ortt LPT Cooling
( 1)
RE
.L51392G01
(1)
.L51 .L5126 267G 7G01 01
Br Bra ack cke et, Supp Suppor ortt LPT Cooling
( 1)
RE
.L51393G01
(1)
.L51220G01
Bra rac cket, Support-LPT Cooling
( 1)
RE
.L51397G01
(1)
----------
Bracket, LPT Cooling
( -)
AD
.L51408G01
(1)
----------
Bolt, Machine
( -)
AD
.AS3237-07
(4)
----------
Strap
( -)
AD
.9134M25P125
(1)
Strap
( 3)
Q TC
.9134M25P125
(1)
Strap
( -)
AD
.9134M25P125
(1)
Strap
(3)
Q TC
.9134M25P33
(1)
.9134M25P125 ---------.9134M25P33
PAGE 5 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
Ol Old d Part Numbe mber
Nomen menclature
Qt Qty y
Ac Acttion
New New Part Number
Qty
----------
Strap
( -)
AD
.9134M25P33
(1)
----------
Strap
( -)
AD
.9134M25P33
(1)
----------
Strap
( -)
AD
.9134M25P33
(1)
682L572G05
Kit, Fuel System
( 1)
RW
682L572G09
(1)
.J646P17D
Bolt, Machine
( 120)
Q TC
.J646P17D
(118)
----------
Bolt, Machine
( -)
AD
.J646P19D
(2)
----------
Bracket, LPT Cooling
( -)
AD
.L51409P01
(1)
682L572G02
Kit, Fuel System
( 1)
RW
682L572G09
(1)
682L500G01
Kit, Joining
( 1)
RM
682L500G01
(1)
.L51 .L5118 189G 9G01 01
Br Bra ack cke et, Supp Suppor ortt LPT Cooling
( 1)
RE
.L51396G01
(1)
OPERATION CODES AD = QTC = RE = REF = RM = RW =
Add Quantit Quantity y Cha Change nge Re Repl plac ace e Refere Reference nce Rema Remain ins s Rewor Rework k
I. Material Interchangeability Physical interchangeability is affected in that the new hardware must be installed as a complete set. Functional interchangeability is not affected by this Service Bulletin. J. Material Material Disposition Disposition Scrap all replaced hardware. K. Material Reidentification Not applicable. applicable. L. References GEAE internal use only: CID: 705544
PAGE 6 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
M. Previous Previous Modifications Modifications None. II. ACCOMPLISHMENT INSTRUCTIONS LPT PT cooling cooling air manifolds manifolds (11 and 18, figure figure 1) as follows: A. Remove L (1) Remove bolt bolts s (2) and retaining retaining strap (3) securi securing ng LPT cooling air air manifol manifold d (1) to LPT cooling air manifold bracket (4). Retain bolts and strap for reuse. (2) Remove bolts (8) and retaini retaining ng strap (9) securing LPT cooling cooling air manifold (11) to LPT cooling air manifold bracket (10). Retain bolts and strap for reuse. (3) Remove bo bolts lts (5), gasket gasket (6), and self-lockin self-locking g nuts (7). Discard gasket gasket (6). Retain bolts and nuts for reuse. bolts ts (12), gaskets gaskets (13), (13), and self-locking self-locking nuts nuts (14). Discard D iscard LPT LPT (4) Remove bol cooling air manifold (11) and gaskets (13). Retain bolts and nuts for reuse. (5) Remove bol bolts ts (15) and retainin retaining g strap (16) (16) securing securing LPT cooling air manifold (18) to LPT cooling air manifold bracket (17). Retain bolts and strap for reuse. (6) Remove bol bolts ts (22) and retainin retaining g strap (23) (23) securing securing LPT cooling air manifold (18) to LPT cooling air manifold bracket (24). Retain bolts and strap for reuse. (7) Remove bol bolts ts (19), gaskets gaskets (20), (20), and self-locking self-locking nuts nuts (21). Discard D iscard LPT LPT cooling air manifold (18) and gaskets (20). Retain bolts and nuts for reuse. B. Replace LPT cooling cooling air air manifold manifold bracket bracket as as follows: follows: (1) Remove bol bolts ts (2, figure 2) and self-lockin self-locking g nuts (3) securing securing LPT LPT cooling air manifold bracket (1) to forward side of HPC aft flange. Discard bracket (1). Retain bolts and nuts for reuse. (2) Lightly co coat at threads and and friction face face of bolts, bolts, PN 9673M86P03 (2), (2), removed remove d in previous step with thread lubricant. lubricant. Using bolts (2), bolthead forward and self-locking nuts (3) secure new LPT cooling support bracket, PN L51396G01 (4), to forward side of HPC aft flange. Tighten nuts (3) to 380-420 lb in. (43.0-47.5 N.m) of torque. C. Replace LPT cooling cooling air air manifold manifold bracket bracket as as follows: follows: (1) Remove bol bolts ts (2, figure 3) and self-locking self-locking nuts (3) securing securing LPT cooling air air manifold bracket (1) to aft side of CRF forward flange. Discard bracket (1). Retain bolts and nuts for reuse.
PAGE 7 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
Left Side 9th Stage LPT Cooling Air Manifold Removal/Installation Figure 1
PAGE 8 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
HPC Aft Flange LPT Cooling Air Manifold Bracket Removal/Installation Figure 2
PAGE 9 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
CRF Forward Flange LPT Cooling Air Manifold Bracket Removal/Installation Figure 3
PAGE 10 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
(2) Lightly co coat at threads and and friction face face of bolts, PN AS3580-5-26 AS3580-5-26 (2), (2), removed remove d in previous step with thread lubricant. lubricant. Using bolts (2), bolthead forward and self-locking nuts (3) secure new LPT cooling support bracket, PN L51392G01 (4), to aft side of CRF forward flange. Tighten nuts to 209-231 lb in. (23.6-26.1 N·m) of torque. D. Replace LPT cooling cooling air air manifold manifold bracket bracket as as follows: follows: (1) Remove bolt bolts s (2, figure 4) 4) securing LPT LPT cooling air air manifold manifold bracket (1) (1) to aft side of extended flange bracket (3). Discard bracket (1). Retain bolts for reuse. (2) Lightly coa coatt threads and and friction friction face of bolts, bolts, PN MS9557-23 MS9557-23 (2), remov removed ed in previous step with thread lubricant. Using bolts (2), bolthead aft, secure new LPT cooling support bracket, PN L51393G01 (4), to aft side of extended flange bracket (3). Ti Tighten ghten bolts finger-tight finger-tight.. E. Replace bracket bracket as follows: (1) Remove bolt bolts s (2, figure 5) and self-locking self-locking nuts nuts (3) securing securing bracket (1) (1) to forward side of CRF aft flange. Discard bracket (1). Retain bolts and nuts for reuse. (2) Lightly coa coatt threads and and friction friction face of bolts, bolts, PN J815P054A J815P054A (2), removed removed in previous step with thread lubricant. lubricant. Using bolts (2), bolthead forward and self-locking nuts (3) secure new LPT cooling support bracket, PN L51397G01 (4), to forward side of CRF aft flange. Tighten bolts finger-tight. follows: F. Install LPT cooling bracket as follows:
NOTE Fuel hose assemblies run clockwise (CW). The No.1 location is the first fuel hose assembly to the right of 12:00 o’clock position, aft looking forward. (1) Locate fu fuel el hose hose assembly assembly 26 and 27, (figure (figure 6). (2) Remove bol bolts ts (2, Detail Detail A) from from fuel hose hose assembly 26 and 27. 27. Discard bolts. bolts. (3) Lightly co coat at threads and and friction face face of new bolts, PN J646P19D J646P19D (2), with thread lubricant. lubricant. Using bolts (2) install new LPT cooling bracket, PN L51409P01 (1), between Fuel hose assembly 26 and 27. Ensure tab of bracket (1) is aft. Tighten bolts finger-tight. G. Install LPT cooling cooling bracket bracket as as follows follows (figure (figure 7): (1) Lightly c coat oat threads and and friction friction face of new bolts, bolts, PN AS3237-07 (2), with thread lubricant. lubricant. Using bolts (2) install new LPT cooling bracket, PN L51408G01 (3), to LPT cooling bracket (1). Tighten bolts finger-tight.
PAGE 11 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
CRF Aft Outer Case Forward Flange LPT Cooling Air Manifold Bracket Removal/Installation Figure 4
PAGE 12 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
CRF Aft Flange LPT Cooling Air Manifold Bracket Removal/Installation Figure 5
PAGE 13 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
Fuel System Kit 682L572, LPT Cooling Bracket Installation Figure 6
PAGE 14 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
LPT Cooling Bracket and Hardware Installation Figure 7
PAGE 15 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
H. Install LPT cooling cooling air manifold (11 and 18, figure figure 1) as follows: follows: (1) Position ne new w LPT cooling air air manifold, manifold, PN L42912G01 L42912G01 (18), in same position position as manifold removed in step A. (7). Lightly coat threads and friction face of bolts, PN AS3237-16 (19), with thread lubricant. Using bolts (19), self-locking nuts (21), removed in step A. (7), and new gaskets, PN 9608M08G52 (20), secure aft flange of manifold (18), two places. Tighten bolts finger-tight. (2) Position ne new w LPT cooling air air manifold, manifold, PN L42913G01 L42913G01 (11), in same position position as manifold removed in step A.(4). Lightly coat threads and friction face of bolts, PN AS3237-16 (12) and AS3238-14 (5) with thread lubricant. lubricant. Using bolts (12), self-locking nuts (14), removed in step A.(4), and new gaskets, PN 9608M08G53 (13), secure aft flange of manifold (11), two places. Using bolts (5), self-locking nuts (7), removed in step A.(3), and new gasket, PN 9608M08G55 (6), secure forward forward flange of manifold (11). Tighten Tighten all bolts finger-tight. coatt threads and and friction face face of bolts, PN AS3237-10 AS3237-10 (22), (22), with thread thread (3) Lightly coa lubricant. lubri cant. Using bolts (22), and retaining strap, PN 9134M25P125 (23), removed in step A.(6), lightly secure LPT cooling manifold (18), to LPT cooling support bracket installed in step E.(2). Tighten bolts finger-tight. coatt threads and and friction face face of bolts, PN AS3237-10 AS3237-10 (15), (15), with thread thread (4) Lightly coa lubricant. lubri cant. Using bolts (15), and retaining strap, PN 9134M25P125 (16), removed in step A.(5), lightly secure LPT cooling manifold (18), to LPT cooling support bracket installed in step D.(2). Tighten bolts finger-tight. (5) Lightly coa coatt threads and friction friction face of of new bolts, PN AS3237-07 AS3237-07 (4, figur figure e 7), with thread lubricant. lubricant. Using bolts (4), (4), and new retaining strap, PN 9134M25P33 (5), lightly secure LPT cooling air manifold (6), to LPT cooling bracket (3), installed in step G.(1). Tighten bolts finger-tight. (6) Lightly coat threads threads and friction friction face of of bolts, PN AS3237-10 AS3237-10 (8, figu figure re 1), with thread lubricant. Using bolts (8), and retaining strap, PN 9134M25P33 (9), removed in step A.(2), lightly secure LPT cooling manifold (11), to LPT cooling support bracket installed in step C.(2). Tighten bolts finger-tight. (7) Lightly co coat at threads threads and friction friction face of bolts, bolts, PN AS3237-10 (2), (2), with thread thread lubricant. Using bolts (2), and retaining strap, PN 9134M25P125 (3), removed in step A.(1), lightly secure LPT cooling manifold (1), to LPT cooling support bracket installed in step B.(2). Tighten bolts finger-tight. (8) Tig Tighten hten self-l self-locking ocking nuts nuts (14 and 21) 21) to 55-70 lb lb in. (6.2-7.9 N.m) N.m) of torque. torque. (9) Tig Tighten hten self-l self-locking ocking nuts nuts (7) to 100-130 100-130 lb in. (11.3-14.7 N.m) of torque. torque. Tighten self-lo self-locking cking nuts (3, figure 3) to 210-230 210-230 lb in. (23.7-26.0 (23.7-26.0 N.m) (10) Tighten of torque. (11) Tighten Tighten bolts (2, figure 4) to 6262-68 68 lb in. (7.0-7.7 (7.0-7.7 N.m) of torque.
PAGE 16 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
(12) Tighten Tighten self-lo self-locking cking nuts (3, figure 5) to 162-178 162-178 lb in. (18.3-20.1 (18.3-20.1 N.m) of torque. Tighten bolts (2, figur figure e 6) as follows: (13) Tighten Tighten en bolts to 100 lb in. (11.3 N.m) of torque. (a) Tight Tighten en bolts bolts to 20 20 lb ft. ft. (27.1 N.m) of torque. (b) Tight (c) Tight Tighten en bolts to 32-35 32-35 lb ft. (43.4-47.5 (43.4-47.5 N.m) of of torque. torque. Safety-wire e bolt to existing existing bolt on on fuel hose hose assembly. assembly. (d) Safety-wir (e) Ensure safe safety-wire ty-wire is not applied applied from one one fuel hose hose assembly to another fuel hose assembly. (14) Tighten Tighten bolts (2, figure 7) to 5555-70 70 lb in. (6.3-7.9 (6.3-7.9 N.m) of torque. Tighten bolts (2, 8, 15, and 22, figure 1) to 55-7 55-70 0 lb in. (6.3-7.9 N.m) N.m) of torque. (15) Tighten (16) Tighten Tighten bolts (4, figure 7) to 5555-70 70 lb in. (6.3-7.9 (6.3-7.9 N.m) of torque. III. COMPLIANCE RECORD Compliance with this Service Bulletin must be entered in local records. The attached Service Bulletin Compliance Record form must be completed and returned to the address indicated on the compliance form.
PAGE 17 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
LM2500-IND-0178 Revision 1 January 19, 2004
9th Stage Air Line Bracket Change
PAGE 18 of 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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