Manual Report Turbine Blade
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699.115
BOG 1.6.3
VOLI.
XNR.:
GAS TURBINE
LM 500 (GEK 99441)
OPERATION AND MAINTENANCE
MANUAL
S0VJERNETS MATERIELKOMMANDO ST.
JAN 1997
31
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GE Marine Engines
GEK 99441 VOL I
OPERATION AND MAINTENANCE
FOR
GE LM500 MARINE AND INDUSTRIAL
GAS TURBINE
GE Marine Engines
Cincinnati, Ohio 45215-6301, USA
GE Marine Engines
GEK 99441 VOL I
TECHNICAL MANUAL
GE LM500 MARINE AND INDUSTRIAL
GAS TURBINE
OPERATION AND MAINTENANCE
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 WRITIEN CONSENT OF GE, INCLUDING,
BUT WITHOUT LIMITATION, IT IS NOT TO BE USED IN THE CREATION, MANUFACTURE, DEVELOPMENT, OR DEVIATION 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 PART. THE INFORMATION CONTAINED IN THIS DOCUMENT MAY ALSO BE CONTROLLED BY U.S. EXPORT CONTROL LAWS. UNAUTHORIZED EXPORT OR REEXPORT IS PROHIBITED.
COPYRIGHT (1992, 2002) GENERAL ELECTRIC COMPANY, USA
NOTE: THIS REVISION REPLACES GEK 99441 VOL I, DATED 1 MAY 1992.
GE Marine Engines
Cincinnati, Ohio 45215-630 1, USA
31 May 2002
GEK 99441
Page A
31 May 2002
NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES
List of Current Changes
Dates of issue for Original and Changed pages are listed in the List of Effective Pages.
Original . . . . . . . . . . .
0 ...........
31 May 2002
Interim Change Notices (ICN) GEK 99441-01 through GEK 99441-05 are incorporated in this revision.
Only those work packages assigned to the manual are listed in this index.
WP
Number
Title
Manual
Change
Number
Cover
0
Title
0
A thru B
Numerical Index of Effective Work Packages ................................ .
0
c
List of Effective Pages .................................................. .
0
D/(E Blank)
Service Bulletin List ................................................... .
0
TOC
Table of Contents ...................................................... .
0
HMWS
Warnings Applicable to Hazardous Materials ................................ .
0
001 00
Alphabetical Index .................................................... .
0
002 00
General Information, Safety Precautions, and Abbreviations .................... .
0
003 00
Description and Specifications ........................................... .
0
004 00
Installation and Removal of Gas Turbine Into/from Shipping Container ........... .
0
005 00
Operating Procedures and Limits (Industrial) ................................ .
0
005 10
Operating Procedures and Limits (Marine) .................................. .
0
006 00
Troubleshooting (Industrial) ............................................. .
0
006 10
Troubleshooting (Marine) ............................................... .
0
007 00
General Maintenance Practices and Inspection Instructions ..................... .
0
008 00
Periodic Inspections and Maintenance ..................................... .
0
009 00
Gas Turbine Inlet Inspection ............................................. .
0
01000
Borescope Inspection .................................................. .
0
011 00
Gas Turbine Exhaust Area and Exhaust Centerbody Inspection, Installation, and
Removal ............................................................. .
0
012 00
Variable Stator Vanes (VSV) System Inspection and Rigging ................... .
0
013 00
Chip Detectors and Drain Plug Removal. Cleaning. Inspection, and Installation .... .
0
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
Page B
31 May 2002
Title
Manual
Change
Number
014 00
Preservation of Installed Gas Turbines ..................................... .
0
015 00
Spectrometric Oil Analysis Program (SOAP) ................................ .
0
016 00
Gas Turbine External Inspection and Special Inspections ...................... .
0
017 00
Compressor and Gas Turbine External Surfaces Cleaning ...................... .
0
018 00
Ignition System Test ................................................... .
0
019 00
Lubrication System Servicing ............................................ .
0
02000
Fuel System Servicing (Marine) .......................................... .
0
021 00
Seal Pressurizing System Components Removal. Cleaning. Inspection. and
Installation (Industrial) ................................................. .
0
Seal Pressurizing and B-Sump Regulating System Components Removal. Cleaning.
Inspection. and Installation (Marine) ...................................... .
0
022 00
Water Wash Hoses and Spray Nozzles Removal and Installation ....... ·.......... .
0
023 00
Ignition System Components Removal. Cleaning. Inspection, and Installation ...... .
0
024 00
Vibration Transducers Removal and Installation (Industrial) .................... .
0
025 00
Thermocouple Harness Segments Removal. Cleaning, Inspection. Testing. and
Installation .......................................................... .
0
026 00
Gas Generator Speed Sensors Removal and Installation ....................... .
0
027 00
Power Turbine (PT) Speed Sensor Assemblies Removal and Installation .......... .
0
028 00
Variable Geometry (VG) Linkage Actuation System Components Removal. Inspection,
and Installation ....................................................... .
0
029 00
Variable Stator Vane Components Removal. Inspection. Repair. and Installation .....
0
03000
Fuel System (Natural Gas) Components Removal. Cleaning. Inspection. and
WP
Number
021 10
Installation (Industrial) ................................................. .
0
Fuel System (Liquid Fuel) Components Removal, Cleaning. Inspection. and
Installation (Marine) ................................................... .
0
Fuel System (Liquid Fuel) Components Removal. Cleaning. Inspection. and
Installation (Marine) ................................................... .
0
031 00
Lubrication System Components Removal. Cleaning. Inspection. and Installation ... .
0
031 10
Lubrication System Components Removal. Cleaning. Inspection. and Installation ... .
0
032 00
Accessory Drive Gearbox Assembly Removal. Inspection. and Installation ........ .
0
033 00
Hydraulic Starter Removal and Installation ................................. .
0
Addendum A
Critical Parts Life Management .......................................... .
0
030 10
030 20
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
PageC
31 May 2002
LIST OF EFFECTIVE PAGES
Total number of pages in this manual is 762 consisting of the following:
WP/Page No.
Change No.
Cover. .... . . . . . .. . .
. .. 0
Blank ... .. . . .
. .....
0
Title. ..... . . . . . . . . . . . .
0
List of Effective
Work Packages . . .
..
0
A -B ... . . . . . . . . . . . . . .
0
List of Effective Pages
()
C.
... . . . . . . . . . . . . .
Service Bulletin List
D .. . . .. . . . . . . . . . . .. 0
()
E Blank ... . . . . . . . . . .
TOC
1 - 2. . . . . . . . . .. . .
..
0
HMWS-1 - HMWS-14 . . . . . 0
001 00
I - 30. . . . . . . ... . . . ..
0
002 00
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003 00
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004 00
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005 00
I - 10. . . ...... . .
0
005 10
I - 12. . . . . . . . ..
.... .
0
006 00
()
I - 25 .. . . . . . . . .
26 Blank ....
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006 10
I - 25. .. . . . . . . . .. . .
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I - 35 ....... .. . .
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I -3 .. . . . . . . .
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WP/Page No.
Change No.
009 00
I -5 ..
....
6 Blank. . . . . . .
..
01000
I -53
. .. . . . . .
54 Blank ... . .....
..
011 00
I-9
. . . . . . ..
10 Blank .. . . . . . .
012 00
.... ..
1 - 13
14 Blank. . . . . . .
..
013 00
.. ....
I-7
8 Blank. .. . . . ...
014 00
I - 12 ..... . . . .
..
015 00
I -5
. . ... . .
6 Blank .. . . . . . . . .
01600
1- 4 ... . .... . ..
017 00
I - 8 ... . . .... .. . .
018 00
1 . . . . . . ..... . . . .
2 Blank. . . . . . .. . . . .
019 00
..
I - 12 . . . .. . . . ..
02000
I - 9 . . . . . . . . . ..
10 Blank .. . . . . . .
..
021 00
I - 19 . . . . . . . .
20 Blank. . . . . . ..
..
021 10
I - 36
.......
..
022 00
I -4 . .
•
•••
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WP/Page No.
Change No.
023 00
I - 34
. . . . . . . .. . .
024 00
I -4 .. . . . . . . . . . . . .. . .
025 00
I - 11 .. . . .
. ... . . .
12 Blank. .....
.....
026 00
I -4 .. . . . . . . . . . . . . . . .
027 00
I -4 ..
. . . . . . . .. . .
028 00
I - 25 ... . . . . .
... . .
26 Blank. ... . .
. . . ..
029 00
I - 32 ... . . . .. . .. . . . .
03000
1 - 17
.....
18 Blank .. ... . . . . . . .. . ..
030 10
I - 33
.....
34 Blank .... . . . ..... . ..
03020
I -32 . .
. .. ... . .. . ..
031 00
I -39
. . ..
40 Blank.
. . . ...... . .
031 10
I -60
.. . . . . .
032 00
I - 18 . . ........ . . . ...
033 00
I -3
..... . . . . .. . ..
4 Blank ..
..
. ..
Addendum A
A-l. . . . . . .
. ..
A-2 Blank
.. . . . .
A-3- A-7.
. . ... . .. . .
A-8 Blank .. . . . . . . . . . . . .
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
0
0
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GEK 99441
31 May 2002
Page D/E Blank
SERVICE BULLETIN LIST
SERVICE
BULLETIN
NUMBER
DATE
INCORPORATED
SERVICE
BULLETIN
NUMBER
DATE
INCORPORATED
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 994.41
TOC
31 May 2002
Page 1 of 2
LM500 GAS TURBINE
OPERATING INSTRUCTIONS AND ON-SITE MAINTENANCE
TABLE OF CONTENTS
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
TABLE OF CONTENTS
Title
WP No.
WP 001 00
Alphabetical Index
DESCRIPTION, INSTALLATION. AND REMOVAL
WP 002 00
General Information. Safety Precautions. and Abbreviations
WP003 00
Description and Specifications
WP004 00
Installation and Removal of Gas Turbine Into/from Shipping Container
OPERATION AND TROUBLESHOOTING
WP005 00
Operating Procedures and Limits (Industrial)
WP 005 10
Operating Procedures and Limits (Marine)
WP 00600
Troubleshooting (Industrial)
WP 006 10
Troubleshooting (Marine)
LEVEL I MAINTENANCE
WP 007 00
General Maintenance Practices and Inspection Instructions
WP 008 00
Periodic Inspections and Maintenance
WP 009 00
Gas Turbine Inlet Inspection
WPOIOOO
Borescope Inspection
WPOII 00
Gas Turbine Exhaust Area and Exhaust Centerbody Inspection, Installation, and Removal
WP 012 00
Variable Stator Vanes (VSV) System Inspection and Rigging
WPOI3 00
Chip Detectors and Drain Plug RemovaL Cleaning, Inspection. and Installation
WP 014 00
Preservation of Installed Gas Turbines
WP 015 00
Spectrometric Oil Analysis Program (SOAP)
WP 016 00
Gas Turbine External Inspection and Special Inspections
WP 017 00
Compressor and Gas Turbine External Surfaces Cleaning
WPOI8 00
Ignition System Test
WP 019 00
Lubrication System Servicing
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
TOC
GEK 99441
Page2
31 May 2002
TABLE OF CONTENTS (Cant)
WP No.
WP 02000
Title
Fuel System Servicing (Marine)
LEVEL 2 MAINTENANCE
WP021 00
Seal Pressurizing System Components RemovaL Cleaning. Inspection. and Installation (Industrial)
WP 021 10
Seal Pressurizing and B-Sump Regulating System Components Removal. Cleaning. Inspection, and
Installation (Marine)
WP 022 00
Water Wash Hoses and Spray Nozzles Removal and Installation
WP 023 00
Ignition System Components Removal. Cleaning. Inspection, and Installation
WP 024 00
Vibration Transducers Removal and Installation (Industrial)
WP025 00
Thermocouple Harness Segments RemovaL Cleaning, Inspection, Testing, and Installation
WP 026 00
Gas Generator Speed Sensors Removal and Installation
WP027 00
Power Turbine (PT) Speed Sensor Assemblies Removal and Installation
WP028 00
Variable Geometry (VG) Linkage Actuation System Components RemovaL Inspection, and Installation
WP029 00
Variable Stator Vane Components Removal. Inspection, Repair. and Installation
WP03000
Fuel System (Natural Gas) Components RemovaL Cleaning. Inspection, and Installation (Industrial)
WP 030 10
Fuel System (Liquid Fuel) Components Removal. Cleaning, Inspection. and Installation (Marine)
WP03020
Fuel System (Liquid Fuel) Components Removal. Cleaning. Inspection, and Installation (Marine)
WP031 00
Lubrication System Components Removal, Cleaning, Inspection. and Installation
WP03110
Lubrication System Components RemovaL Cleaning. Inspection, and Installation
WP032 00
Accessory Drive Gearbox Assembly Removal. Inspection. and Installation
WP033 00
Hydraulic Starter
ADDENDUM
A
Critical Parts Life Management
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
HMWS-1
GEK 99441
Page 1 of 14
31 May 2002
Warnings Applicable to Hazardous Materials
Warnings in this manual alert personnel to hazards associated with the use of hazardous materials. Consult your local safety and health staff concerning any questions regarding hazardous materials, Material
Safety Data Sheets (MSDS), personal protective equipment requirements, appropriate handling and
emergency procedures, and disposal guidance.
Under the heading "HAZARDOUS MATERIALS WARNINGS," complete warnings, including related icon(s)
and numeric identifier, are provided for hazardous materials used in this manual.
In the text of the manual, the caption "WARNING" is not used for hazardous material warnings. Hazards
are cited with appropriate icon(s), the nomenclature of the hazardous material, and the numeric identifier
that relates to the complete warnings. Users of hazardous materials shall refer to the complete warnings.
EXPLANATION OF HAZARDOUS MATERIALS WARNING ICONS
Biological
The abstract symbol bug shows that a material may contain bacteria or viruses that
present a danger to life or health.
Chemical
The symbol of a liquid dripping onto a hand shows that the material will cause burns or
irritation to human skin or tissue.
Cryogenic
The symbol of a hand in a block of ice shows that the material is extremely cold and can
injure human skin or tissue.
Explosion
This rapidly expanding symbol shows that the material may explode if subjected to high
temperature, sources of ignition, or high pressure.
Eye Protection
The symbol of a person wearing goggles shows that the material will injure the eyes.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-2
31 May 2002
EXPLANATION OF HAZARDOUS MATERIALS WARNING ICONS (Cont)
Fire
The symbol of a fire shows that the material may ignite and cause burns.
Poison
The symbol of a skull and crossbones shows that the material is poisonous or is a danger
to life.
Radiation
The symbol of three circular wedges shows that a material emits radioactive energy and
can injure human tissue or organs.
Vapor
The symbol of a human figure in a cloud shows that material vapors present a danger to
life or health.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
HMWS-3
GEK 99441
31 May 2002
HAZARDOUS MATERIALS WARNINGS
Acetone, 0-A-51
•
•
•
•
•
•
•
Flammable - do not use near open flames. near welding areas. or on hot surfaces.
Do not smoke while using it. and do not use it where
others are smoking.
Prolonged inhalation of vapor can irritate eyes and
mucous membranes and can cause dizziness and
headache. Ifvapors cause drowsiness. go to fresh air.
If any liquid contacts skin or eyes. immediately flush
affected area thoroughly with water. Immediately
remove solvent-saturated clothing.
When handling large quantities of liquid (more than a
gallon). use at air-exhausted workbench. Wear
approved gloves.
Store solvent and dispose of liquid-soaked rags in
approved metal safety container.
Metal containers of solvent must be grounded to
maintain electrical continuity.
Nitric Acid, 0-N-350
•
•
•
•
•
•
4
Highly reactive- do not mix with combustible organics or other oxidizable materials such as wood. paper,
and cloth. When heated, toxic gases are released.
When mixing solutions, add acid to water, not water
to acid.
Contact of skin with liquid or inhalation of mist can
cause severe burns. respiratory tract irritation. and
chronic bronchitis.
If any solution. liquid, or mist contacts skin or eyes.
flush affected area throughly with water. Immediately
change any contaminated clothing. If mist is inhaled,
go to fresh air. Immediately get medical help.
If handling solution or concentrated liquid in airexhausted covered tank, wear approved gloves and
apron, and wear goggles or face shield.
When handling solution or concentrated liquid in
open tank, wear approved respirator. full-body clothing. gloves. and goggles.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
HMWS-4
GEK 99441
31 May 2002
5
Phosphoric Acid, 0-0-670
•
•
•
•
•
•
Contact with metals releases flammable hydrogen
gas.
When mixing solutions. add acid to water, not water
to acid.
Do not have any contact with liquid. it is very corrosive. Contact with liquid will hurn any exposed tissue. Inhalation of mist can irriate nose and throat.
If any liquid contacts skin or eyes. immediately flush
affected area thoroughly with water. Get medical
attention immediately. Immediately remove acid-saturated clothing.
When handling concentrated or diluted liquid in airexhausted tank. wear approved gloves. and wear goggles or face shield.
When handling concentrated or diluted liquid in open
unexhausted tank. wear approved respirator, gloves.
and goggles.
Isopropyl Alcohol, TT-1-735
•
•
•
•
•
•
•
11
Flammable - do not use near open flames. near welding areas, or on hot surfaces.
Do not smoke when using it, and do not use it where
others are smoking.
Inhalation of vapors can cause drowsiness. dizziness.
and headache. Contact of liquid with skin may cause
dermatitis and irritation.
If any liquid contacts skin or eyes. immediately flush
affected area thoroughly with water. Remove solventsaturated clothing. If vapors cause drowsiness, go to
fresh air.
When handling large quantities (greater than one gallon), work at air-exhausted workbench or covered
tank.
Store solvent and dispose of liquid-soaked clothes in
approved metal safety container.
Metal containers of liquid must he grounded to maintain electrical continuity.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
HMWS-5
GEK 99441
31 May 2002
8&8 3100 Cleaner-Water Solution
•
•
•
•
•
•
•
•
•
•
18
B&B 3100 cleaner shall be mixed with water (or
water antifreeze solution) only in the proportions
specified.
For engines installed in aircraft, close off appropriate
air bleed ducts to cockpit/cabin to prevent entrance of
cleaning solution or gases during washing and drying
cycles.
For engines installed in aircraft, make sure that compressor is rinsed and dried for the periods specified so
that cleaning solution is not trapped in passages, crevices, and other areas of the engine.
Solution irritates eyes. Wear splashproof goggles or
face shield when using solution.
Use protective gloves and clothing. Repeated or prolonged contact will dry the skin and will cause irritation and dermatitis.
If clothing becomes contaminated with cleaning solution, remove affected clothing. Wash affected skin
areas with plenty of water.
Use solution with adequate ventilation. Repeated or
prolonged breathing of vapors may irritate mucous
membranes and may cause headaches and dizziness.
Persons with known respiratory irritation should get
medical advice before using cleaning solution.
Avoid open f1ames, heat, smoking. or other ignition
sources in the areas of storage and use.
Spills should be immediately cleaned up (using
squeegee or absorbent material) to prevent evaporation of vapors and slippery f1oors. Dispose of spillage
according to local safety regulations.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-6
31 May 2002
Calibrating Fluid, MIL-C-7024
•
•
•
•
•
•
Combustible near sparks. open flames. welding areas.
hot surfaces. other sources of ignition. or while smokmg.
Inhalation may cause irritation or burning of respiratory system.
Contact with eyes/face/skin may cause severe irritation or burning.
Ingestion may cause irritation or burning of digestive
system.
Personal protective equipment required when handling or using this material.
Thermal decomposition may release toxic by-products.
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
•
•
•
•
•
21
32
Combustible- do not use near open flames, near
welding areas, or on hot surfaces.
Prolonged contact of skin with liquid can cause dermatitis. Repeated inhalation of vapor can irritate nose
and throat and can cause dizziness.
If any liquid contacts skin or eyes, immediately flush
affected area thoroughly with water. Remove solventsaturated clothing. If vapors cause dizziness. go to
fresh air.
When handling liquid or when applying it in an airexhausted. partially covered tank. wear approved
gloves and goggles.
When handling liquid or when applying it at unexhausted. uncovered tank or workbench, wear
approved respirator. gloves, and goggles.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-7
31 May 2002
,
General Purpose Detergents,
MIL-D-16791
40
•
•
•
Do not take internally.
Do not get in eyes.
Wear goggles or face shield when handling.
66
Lubricating Oil
•
•
•
•
•
If oil is decomposed by heat, toxic gases are released.
Prolonged contact with liquid or mist may cause dermatitis and irritation.
If there is any prolonged contact with skin, wash area
with soap and water. If solution contacts eyes, flush
eyes with water immediately. Remove saturated clothmg.
If oil is swallowed, do not try to vomit. Get immediate
medical attention.
When handling liquid. wear rubber gloves. If prolonged contact with mist is likely, wear approved respirator.
Corrosion Preventive
Compound, Petrolatum,
Hot Application,
MIL-C-11796
69
•
•
•
•
•
If solution is decomposed by heat, toxic gases are
released.
Prolonged contact with solution or mist can cause dermatitis and irritation.
If there is any prolonged contact with skin. wash contacted area with soap and water. If solution contacts
eyes, flush eyes with water immediately. Remove saturated clothing.
If solution is swallowed, do not try to vomit. Get
immediate medical help.
When handling solution. wear rubber gloves. If prolonged contact with mist is likely, wear approved respirator.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-8
31 May 2002
Hydraulic Fluid
•
Inhalation may cause irritation or burning of repsiratory system.
Contact with eyes/face/skin may cause irritation or
burning.
Ingestion may cause irritation or burning of digestive
system.
Personal protective equipment required when handling or using this material.
Thermal decomposition releases toxic by-products.
•
•
•
•
.
•
•
•
•
•
•
•
71
Methanol, 0-M-232
83
Flammable - do not use near open flames, near welding areas, or on hot surfaces.
Do not smoke when using it. and do not use it where
others are smoking.
Prolonged or repeated inhalation of vapor can cause
eye irritation, drowsiness, and headache. Ingestion
may be fatal or may cause eye damage.
If vapor contacts eyes. immediately flush eyes with
large amounts of water. Immediately remove solventsaturated clothing. If vapors cause drowsiness. go to
fresh air.
When handling or applying liquid at air-exhausted
workbench. wear approved goggles.
When handling or applying liquid at unexhausted
workbench. wear approved respirator and goggles.
Solution of 40o/c methanol and 60lf'c water is combustible.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-9
31 May 2002
Miller-Stephenson Solvent
MS-160 (Or Freon, TP-35)
•
•
•
•
•
•
Naphtha
•
•
•
•
•
•
•
85
Vapors arc harmful; do not use solvent near open
flames or on hot surfaces. Use it only with adequate
ventilation.
Do not use it near welding areas. a source of concentrated ultraviolet rays. Intense ultraviolet rays can
cause the formation of toxic gas.
Do not smoke when using it.
Do not take it internally.
Prolonged or repeated contact can cause skin irritation. Wear approved gloves and goggles (or face
shield) when handling, and wash hands thoroughly
after handling.
Store it in approved metal safety containers.
88
Combustible- do not use it near welding areas. near
open flames, or on hot surfaces.
Avoid prolonged or repeated contact with liquid.
Contact of skin with liquid can cause irritation and
dermatitis. Inhalation of vapors can cause irritation,
giddiness. and drowsiness.
If liquid contacts eyes. t1ush eyes thoroughly with
water. If there is any prolonged skin contact. wash
contacted area with soap and water. If vapors cause
drowsiness, go to fresh air. Remove solvent-saturated
clothing. If liquid is swallowed, do not try to vomit.
Get medical attention.
When handling liquid in an air-exhausted, partially
covered tank. wear approved gloves.
When handling liquid in an open, unexhausted container. wear rubber gloves and goggles. If contact with
vapor is likely. wear an approved respirator. Dispose
of liquid-soaked rags in approved metal container.
Metal containers of liquid must be grounded to maintain electrical continuity.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
HMWS-10
GEK 99441
31 May 2002
RTV Silicone Rubber Adhesive/Sealant,
MIL-A-461 06 or MIL-A-461 06A
RTV-60 Silicone Rubber Potting Compound,
MIL-1-468388
•
•
•
•
Vapor released during curing is combustible. Do not
use near open flames. near welding areas. or on hot
surfaces.
Vapor is corrosive. Contact of vapor with skin or eyes
will cause burns. Inhalation of vapor may cause
severe nose and throat irritation; repeated inhalation
may result in chronic bronchitis.
If any vapor contacts skin or eyes, immediately tlush
affected area thoroughly with water. If vapors cause
irritation. go to fresh air. Get medical attention.
When mixing uncured rubber. and during curing of
rubber wear approved respirator. gloves, and goggles
or face shield.
Tetrachloroethylene
(Perchloroethylene), 0-T-236
•
•
•
•
•
95
99
Repeated or prolonged contact with liquid or inhalation of vapor can cause skin and eye irritation, dermatitis. narcotic effects, and liver and kidney damage.
After prolonged skin contact. wash contacted area
with soap and water. Remove contaminated clothing.
If vapors cause irritation, go to fresh air. For prolonged over-exposure. get medical help.
When handling liquid in vapor-degreasing tank with
hinged cover and air exhaust. or at air-exhausted
workbench, wear approved gloves and goggles to prevent contact with liquid.
When handling liquid at open. unexhausted workbench. wear approved respirator, gloves. and goggles.
Dispose of liquid-soaked rags in approved metal container.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-11
31 May 2002
Trichloroethane, 0-T-620
•
•
•
•
•
•
Do not use near open flames, welding areas, or on
very hot surfaces. Do not smoke when using it. Heat
and flames can cause the formation of phosgene gas
which is injurious to the lungs.
Repeated or prolonged contact with liquid or inhalation of vapor can cause skin and eye irritation, dermatitis, narcotic effects. and heart damage.
After prolonged skin contact. wash contacted area
with soap and water. Remove contaminated clothing.
If vapors cause irritation. go to fresh air. Get medical
attention for overexposure of skin and eyes.
When handling liquid in vapor-degreasing tank with
hinged cover and air exhaust. or at air-exhausted
workbench, wear approved gloves and goggles.
When handling liquid at open. unexhausted workbench. wear approved respirator, gloves. and goggles.
Dispose of liquid-soaked rags in approved metal container.
Trichlorotrifluoroethane,
MIL-C-81302
•
•
•
•
•
122
124
Repeated or prolonged contact with liquid or inhalation of vapor can cause skin and eye irritation. dermatitis. drowsiness. and heart damage.
After prolonged skin contact. wash contacted area
with soap and water. Remove contaminated clothing.
If vapors cause irritation, go to fresh air: get medical
attention.
When handling liquid in vapor-degreasing tank with
hinged cover and air-exhaust, or at air-exhausted
workbench. wear approved gloves and goggles.
When handling liquid at open. unexhausted workbench. wear approved respirator. gloves. and goggles.
Dispose of liquid-soaked rags in approved metal
container.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
HMWS-12
GEK 99441
31 May 2002
Penetrating Oil
•
•
•
•
Do not use near open flames or other heat source
including smoking.
Do not have any contact with liquid or vapor. Contact
of eyes with vapor or liquid can cause severe irritation. Prolonged inhalation of vapor may cause headache, dizziness. and nausea.
If liquid contacts eyes. flush them throughly with
water. After prolonged skin contact, wash contacted
area with soap and water. If vapors cause dizziness.
go to fresh air.
When handling or applying liquid, wear goggles or
face shield. If prolonged exposure to vapor is likely,
wear approved respirator.
Chemical Conversion Materials
for Coating Aluminum and
Aluminum Alloys, MIL-C-81706
•
•
•
•
•
•
•
•
234
281
Highly reactive- do not mix with oxidizable materials
such as cloth. paper. and wood.
When mixing solutions. add acid to water. not water
to acid.
Contact with powder or vapors can cause severe skin
and eye irritation, and skin ulcers. Repeated or prolonged inhalation or ingestion can result in nasal and
kidney damage.
If any liquid or powder contacts skin or eyes, immediately flush affected area thoroughly with water.
Immediately change any contaminated clothing. If
skin disorders appear. get medical attention.
When handling powder or liquid at air-exhausted
workbench or tank, wear approved gloves and apron.
When handling powder or liquid at unexhausted
workbench. wear approved respirator, gloves, and
apron.
Do not eat. smoke. or carry smoking materials in
areas where powder is handled.
Contains chromates. Follow approved toxic waste
disposal procedures.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
HMWS-13
31 May 2002
292
Aviation Turbine Fuel (Jet Fuel)
•
•
•
•
•
•
•
Flammable near sparks. open flames. hot surfaces,
other sources of ignition. or while smoking.
Inhalation may cause irritation or burning of respiratory system.
Contact with eyes/face/skin may cause irritation or
burning.
Ingestion may cause irritation or burning of the
digestive system.
Material contains chemicals known to be
carcmogemc.
Personal protective equipment required when handling or using this material.
Thermal decomposition may release toxic byproducts
R-MC or Rivenaes R-MC
Cleaner/Mixture
•
•
•
•
403
Do not use the Rivenaes R-MC cleaner/mixture near
flames or heat.
The cleaner/mixture, when mixed with isopropyl
alcohol or methanol, is a flammable mixture.
Do not breathe the fumes released from this cleaner/
mixture. Make sure you have a good flow of air. The
fumes can make you sick.
Do not let the cleaner/mixture stay on your skin
because the cleaner/mixture can dry your skin or can
cause injury to your eyes.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
HMWS-14
GEK 99441
31 May 2002
_
-;?-
•
•
Contact with these materials can cause irritation to
skin and eyes.
After any prolonged skin contact, wash contacted area
with soap and water. If material contacts eyes, flush
them thoroughly with water.
Natural Gas
•
•
•
Antiseize Compound
Braycote 655
416
4018
Provide adequate ventilation to avoid concentration of
potentially explosive fumes or vapor.
Enclosed areas should be monitored for oxygen content and explosive vapors. If oxygen content falls
below 19.5 percent. self-contained breathing equipment is required. Cartridge or canister respirators
must not be used.
Never use open tlame to detect leaks. use a soap and
water solution.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 1 of 30
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
ALPHABETICAL INDEX
Effectivity:
L32119G01 /-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Alphabetical Index .................................................................. .
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
2
GEK 99441
001 00
31 May 2002
Page2
INDEX
Subject
Volume
Work
Package
A
A-Sump Pressure Valve Air Metal Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
A-Sump Pressure Valve Air Metal Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
A-Sump Scavenge Pump and Components
(U2119GO I /-G02/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Servicing ............................................................
A-Sump Scavenge Pump and Components (L32119G05)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Servicing ............................................................
Abbreviations. General Information, Safety Precautions.
and Unit Conversion ...................................................
Abnormal Acceleration to Max Power (Industrial) ..............................
Abnormal Acceleration to Max Power (Marine) ...............................
Abnormal Deceleration from High Power (Industrial) ...........................
Abnormal Deceleration from High Power (Marine) .............................
Abnormal Running Conditions (Industrial)
Compressor Stall .....................................................
Flameout ............................................................
Fuel Flow ...........................................................
Hot Start ............................................................
Oil Pressure .........................................................
Overspeed ...........................................................
Overtemperature ......................................................
Vibrations ...........................................................
.
.
.
.
.
I
I
I
I
WP 021
WP 021
WP 021
WP 021
WP 021
00
00
00
00
00
.
.
.
.
.
I
I
I
I
I
WP021
WP021
WP021
WP021
WP021
10
10
10
10
10
.
.
.
.
.
I
WP031 00
WP031 00
WP031 00
WP031 00
WP019 00
.
.
.
.
.
I
I
.
.
.
.
.
.
.
.
.
.
.
.
.
I
I
I
I
I
WP03110
WP031 10
WP031 10
WP031 10
WP 019 00
WP002
WP006
WP006
WP006
WP 006
00
00
10
00
10
WP005
WP005
WP005
WP005
WP005
WP005
WP005
WP005
00
00
00
00
00
00
00
00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page3
INDEX (Cont)
Subject
Volume
Abnormal Running Conditions (Marine)
Compressor Stall ..................................................... .
Flameout ............................................................ .
Fuel Flow ........................................................... .
Hot Start ............................................................ .
Oil Pressure ......................................................... .
Overspeed ........................................................... .
Overtemperature ...................................................... .
Vibrations ........................................................... .
Accessory Drive Gearbox Assembly and Components
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Accessory Drive Section Description ........................................ .
Actuation System Components. Variable Geometry (VG) Linkage
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Actuator Arms, Inlet Guide Vanes (IGV)
Inspection ........................................................... .
Replacement ......................................................... .
Actuator Arms. Stages I through 5 Vane
Inspection ........................................................... .
Actuator Ring (IGV)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Actuator Rings. Stages I through 5
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Actuator System Linkage Assemblies
Adjustment .......................................................... .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Actuators Hose Assemblies, Variable Geometry (VG)
Installation .......................................................... .
Removal ............................................................ .
Actuators, Variable Geometry (VG)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Replacement of Nipples, Rod-End Bearing. Reducer, and Plug ................. .
I
I
Work
Package
WP 005
WP005
WP 005
WP005
WP 005
WP 005
WP 005
WP 005
10
10
10
10
10
10
10
10
WP032 00
WP03200
WP032 00
WP003 00
WP028 00
WP028 00
WP028 00
WP029 00
WP029 00
WP029 00
I
I
I
I
WP029 00
WP029 00
WP029 00
WP029 00
WP02900
WP029 00
WP029
WP029
WP029
WP029
00
00
00
00
WP028 00
WP028 00
WP028
WP028
WP028
WP028
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00
00
00
00
001 00
GEK 99441
Page4
31 May 2002
INDEX (Cant)
Volume
Subject
Air Regulator Valve Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Air System Description ...................................................
Alodine 1200 Touchup ...................................................
Arrangement of Technical Manual ..........................................
.
.
.
.
.
.
.
.
Work
Package
I
I
I
I
I
I
I
I
WP 021
WP021
WP 021
WP 021
WP021
WP003
WP007
WP002
10
10
10
10
10
00
00
00
I
I
I
I
I
WP021
WP021
WP021
WP021
WP021
10
10
10
10
10
I
I
I
I
WP021
WP021
WP 021
WP021
WP 021
10
10
10
10
10
I
I
WP 021
WP021
WP021
WP003
10
10
10
00
I
I
WP023 00
WP023 00
WP023 00
WP023 00
WP007 00
WP007 00
WPOI4 00
WP007 00
I
WP 030 10
WP030 10
WP030 10
B
B-Sump Oil Tube (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
B-Sump Regulating System Components (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
B-Sump Regulator Valve (Marine)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Basic Gas Turbine Operation .............................................. .
Beam Assembly. Support (L32119GO l/-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Bearing Handling Practices ................................................ .
Bearing Installation Practices .............................................. .
Bearings. Oil-Wetting (Slushing), Gas Turbine ................................ .
Blending Procedures ..................................................... .
Block. Fuel Distributor (Marine) (L32119GOI/-G03/-G04)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Borescope Inspection
Combustion Liner ..................................................... .
Compressor Casing .................................................... .
Compressor Rotor Blades ............................................... .
WP 010 00
WP 010 00
WP01000
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 5
INDEX (Cant)
Volume
Subject
Borescope Inspection (Cont)
Fuel Injectors ........................................................
Inlet Guide Vanes .....................................................
Post Bore scope Inspection Procedures .....................................
Stage I High-Pressure Turbine (HPT) Rotor Blades ..........................
Stage I Turbine Nozzle .................................................
Stages I and 2 High-Pressure Turbine (HPT) Rotor Blades .....................
Stages 3 Through 5 Low-Pressure Turbine (LPT) Rotor Blades .................
Stationary Vanes ......................................................
Variable Vanes .......................................................
Borescope. Kit Setup .....................................................
Bracket Assembly, Exciter (U21 19G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Bushings and Plugs, Igniter
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Work
Package
.
.
.
.
.
.
.
.
.
.
WPOIOOO
WPOIOOO
WP 010 00
WP 010 00
WP 010 00
WP 010 00
WP 010 00
WP 010 00
WPOIOOO
WPOIOOO
.
.
.
.
WP023
WP023
WP023
WP023
.I
00
00
00
00
.
.
.
WP023 00
WP023 00
WP023 00
.
.
.
.
.
WP 021
WP 021
WP 021
WP 021
WP 021
00
00
00
00
00
.
.
.
.
.
WP021
WP 021
WP 021
WP 021
WP021
10
10
10
10
10
.
.
.
.
.
WP 021
WP 021
WP 021
WP021
WP 021
00
00
00
00
00
.
.
.
.
.
WP 021
WP021
WP 021
WP021
WP 021
10
10
10
10
10
c
C-Sump Aft Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
C-Sump Aft Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
C-Sump Forward Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
C-Sump Forward Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
I
I
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
Page6
31 May 2002
INDEX (Cant)
Subject
Volume
Cable. Variable Geometry (VG) Feedback
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Cautions, Warnings, and Notes .............................................
Centerbody, Exhaust
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Replacement of Anchor Nuts ............................................
Centervent Tube, Inspection ...............................................
Changed/Revised, Work Package Numbers ...................................
Changes to Technical Manual ..............................................
Characteristics, Gas Turbine ...............................................
Chip Detectors
Cleaning ............................................................
General Information ...................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Cleaning of Fuel System When Contaminated with Water ........................
Cleaning of Gas Turbine External Surfaces ...................................
Cleaning and Rinsing, Compressor ..........................................
Cleaning and Rinsing, Solutions. Preparation ..................................
Cold-Working ..........................................................
Combustion Section Description ............................................
Compressor Cleaning and Rinsing ..........................................
Compressor Section, Description ...........................................
Compressor Stall (Abnormal Running Condition) (Industrial) .....................
Compressor Stall (Abnormal Running Condition) (Marine) ......................
Consumable Materials ....................................................
Control Assembly, Variable Geometry (VG)
Adjustment ..........................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Replacement .........................................................
Control System Operation, Gas Turbine ......................................
Conversion. Unit ........................................................
Components Description. Gas Turbine .......................................
Compressor Stall (Abnormal Running Condition) (Industrial) .....................
Compressor Stall (Abnormal Running Condition) (Marine) ......................
Cotter Pin Practices ......................................................
Crack Description .......................................................
Work
Package
.
.
.
.
I
I
I
I
WP028
WP028
WP028
WP002
.
.
.
.
.
.
.
.
I
I
I
I
I
I
I
WPOII 00
WPOII 00
WPOII 00
WPOII 00
WPOII 00
WP002 00
WP002 00
WP 003 00
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
I
I
I
I
I
I
I
.
.
.
.
.
.
.
.
.
.
.
.
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
00
00
00
00
WP013 00
WP 013 00
WP013 00
WP013 00
WP013 00
WP020 00
WP 017 00
WP 017 00
WP 017 00
WP007 00
WP003 00
WP 017 00
WP003 00
WP005 00
WP 005 10
WP002 00
WP028 00
WP028 00
WP028 00
WP028 00
WP 028 00
WP003 00
WP002 00
WP003 00
WP005 00
WP 005 10
WP007 00
WP007 00
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page?
INDEX (Cont)
Subject
Volume
Critical Parts Life Management
Definitions .......................................................... .
Affected Parts ........................................................ .
Parameters To Be Tracked .............................................. .
Calculating Accumulated Cycles and Recording Data
Work
Package
Addendum
Addendum
Addendum
Addendum
A
A
A
A
D
Data. Organization of Inspection ............................................
Definitions of Inspection Terms ............................................
Degreasing. Vapor .......................................................
Description and Specifications .............................................
Description. Gas Turbine
Components .........................................................
Systems .............................................................
Description of Shipping Container ..........................................
Detectors. Chip
Cleaning ............................................................
General Information ...................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Distributor Block, Fuel (Marine) (L32119GO I/-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Distributor, Fuel (Marine) (L32119GOI/-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Drain Plug
Cleaning ............................................................
General Information ...................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Drain Separator Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
.
.
.
.
WP007
WP007
WP007
WP003
.
.
.
WP003 00
WP003 00
WP004 00
.
.
.
.
.
I
I
WP013
WP 013
WP 013
WP 013
WPOJ3
00
00
00
00
00
00
00
00
00
.
.
.
WP030 10
WP 030 10
WP030 10
.
.
.
WP 030 10
WP 030 10
WP030 10
.
.
.
.
.
WPOI3
WP 013
WPOJ3
WPOI3
WPOJ3
00
00
00
00
00
.
.
.
.
.
WP 021
WP 021
WP021
WP 021
WP 021
00
00
00
00
00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 8
INDEX (Cant)
Subject
Volume
Drain Separator Tube (Marine)
Cleaning ............................................................ .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.............................................................
Work
Package
I
I
I
I
WP021
WP021
WP021
WP021
WP 021
10
10
10
10
10
I
WP003 00
I
I
I
WP028
WP028
WP028
WP005
WP005
00
00
00
00
10
WP031
WP 031
WP 031
WP031
WP002
10
10
10
10
00
E
Electrical System Description .............................................. .
Element, Hydraulic Filter
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Emergency Shutdown Procedure (Industrial) .................................. .
Emergency Shutdown Procedure (Marine) .................................... .
Engine Oil Tank and Tubing (L32119G05)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Equipment, Support. ..................................................... .
Evaluation of Gas Turbine Part Serviceability Using
the Borescope ........................................................ .
Exchanger, Heat (L321 19005)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Exciter Bracket Assembly (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Exciter, Ignition
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Exhaust Centerbody
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Replacement of Anchor Nuts ............................................ .
Expendables ........................................................... .
Extent and Methods of Inspection ........................................... .
.I
I
I
I
I
I
WP007 00
I
I
WP031 10
WP 031 10
WP03110
WP031 10
I
I
I
WP023
WP023
WP023
WP023
00
00
00
00
WP023
WP023
WP023
WP023
00
00
00
00
I
I
I
I
WP011 00
WPOll 00
WPOll 00
WP011 00
WP002 00
WP007 00
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page9
INDEX (Cont)
Subject
Volume
Work
Package
F
Feed Tubes. Fuel (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Feedback Cable, Variable Geometry (VG)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Filter Assembly. Fuel (Marine) (L32119GOI/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Filter Assembly. Fuel (Marine) (L32119G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Filter Element, Hydraulic
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Filter, Lube, Servicing ....................................................
Fittings
Installation Practices of Non-Positioning Type ..............................
Installation Practices of Positioning Type ..................................
Flameout (Abnormal Running Condition) (Industrial) ...........................
Flameout (Abnormal Running Condition) (Marine) .............................
Flameout. Troubleshooting (Industrial) ......................................
Flameout. Troubleshooting (Marine) ........................................
Front Frame Description ..................................................
Fuel Distributor (Marine) (L321 19GO I /-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Fuel Distributor Block (Marine) (L32119GO l/-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
.
.
.
.
WP030 00
WP03000
WP03000
WP03000
.
.
.
WP028 00
WP028 00
WP028 00
.
.
.
.
WP 030
WP030
WP 030
WP 030
.
.
.
.
WP030 20
WP030 20
WP030 20
WP030 20
.
.
.
.
WP028
WP028
WP028
WP 019
00
00
00
00
.
.
.
.
.
.
.
WP007
WP007
WP005
WP005
WP006
WP006
WP003
00
00
00
10
00
10
00
.
.
.
WP 030 10
WP 030 10
WP 030 10
.
.
.
WP 030 10
WP030 10
WP 030 10
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
10
10
10
10
001 00
GEK 99441
Page 10
31 May 2002
INDEX (Cant)
Volume
Subject
Fuel Feed Tubes (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Filter Assembly (Marine) (L32119GOI/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Filter Assembly (Marine) (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Flow (Abnormal Running Condition) (Industrial) .......................... .
Fuel Flow (Abnormal Running Condition) (Marine) ............................ .
Fuel Injector Hose Assemblies (Marine) (L321 !9GO I/-G03/-G04)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Injectors (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Injectors (Marine) (L32119G05/-G06)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Manifold Assemblies (Marine) (L32119G05/-G06)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Pump, Main (Marine) (L32119GO I/-G03/-G04)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Fuel Pump. Main (Marine) (L321 19G05/-G06)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Work
Package
WP03000
WP03000
WP03000
WP03000
I
I
I
WP030 10
WP030 10
WP 030 10
WP03010
I
I
WP030 20
WP030 20
WP03020
WP 030 20
WP005 00
WP 005 10
I
I
I
I
I
WP030 10
WP030 10
WP030 10
I
I
I
I
WP03000
WP03000
WP 03000
WP030 00
I
I
WP030 20
WP030 20
WP030 20
I
WP030 20
WP030 20
WP030 20
I
I
WP 030 10
WP030 10
WP030 10
I
I
I
WP030 20
WP030 20
WP030 20
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 11
INDEX (Cant)
Volume
Subject
Fuel System
Cleaning When Contaminated With Water (Marine) ..........................
Description ..........................................................
Gas Turbine Systems Description ........................................
Preservation (Marine) ..................................................
Servicing (Marine) ....................................................
Servicing When Bypass Indicator Button Has Popped (Marine) .................
Fuel System (Liquid Fuel) Components (Marine) (U2119GOI/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Fuel System (Liquid Fuel) Components (Marine) (U2119G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Fuel System (Natural Gas) Components (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
.
.
.
.
.
.
.
.
.
.
I
I
Work
Package
WP02000
WP003 00
WP003 00
WP014 00
WP020 00
WP02000
WP 030
WP 030
WP 030
WP 030
10
10
10
10
.
.
.
.
WP030
WP030
WP030
WP030
20
20
20
20
.
.
.
.
WP03000
WP03000
WP03000
WP030 00
I
I
G
Gas Generator Speed Sensors
Installation ..........................................................
Removal ............................................................
Gas Turbine
Abnormal Running Conditions (Industrial) .................................
Abnormal Running Condition (Marine) ....................................
Basic Operation ......................................................
Characteristics .......................................................
Cleaning of External Surfaces ...........................................
Components Description ...............................................
Compressor Section ...................................................
Control System Operation ..............................................
Does Not Reach Idle or Slow Acceleration to Idle (Industrial) ..................
Does Not Reach Idle or Slow Acceleration to Idle (Marine) ....................
Emergency Shutdown (Industrial) ........................................
Emergency Shutdown Procedure (Marine) .................................
Exhaust Area Inspection ................................................
External Inspection ....................................................
External Surfaces, Cleaning .............................................
Handling Equipment. ..................................................
Inlet Inspection .......................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
I
I
I
WP026 00
WP026 00
WP005 00
WP 005 10
WP003 00
WP00300
WP 017 00
WP00300
WP00300
WP003 00
WP006 00
WP006 10
WP005 00
WP 005 10
WPOll 00
WP 016 00
WP 017 00
WP 004 00
WP009 00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 12
INDEX (Cant)
Subject
Volume
Gas Turbine (Coni)
Inspection and Prestart Checks (Industrial) ................................. .
Installation into Shipping Container. ...................................... .
Motoring Procedure (Marine) ............................................ .
Normal Operating Ranges and Limits (Industrial) ............................ .
Normal Operating Ranges and Limits (Marine) .............................. .
Normal Operation (Marine) ............................................. .
Normal Shutdown Procedure (Marine) .................................... .
Operation (Marine) .................................................... .
Points of Reference and Orientation ....................................... .
Preservation ......................................................... .
Prestart Checks and Inspection (Industrial) ................................. .
Prestart Checks (Marine) ............................................... .
Principles of Operation ................................................. .
Removal from Shipping Container ........................................ .
Shutdown (Industrial) .................................................. .
Special Inspections .................................................... .
Storage and Maintenance While in Shipping Container ....................... .
Systems Description ................................................... .
Gas Turbine Components Description
Accessory Drive Section ............................................... .
Combustion Section ................................................... .
Compressor Section ................................................... .
Front Frame ......................................................... .
High-Pressure Turbine Section ........................................... .
Power Turbine Section ................................................. .
Gas Turbine Operation (Marine) ............................................ .
Gas Turbine Systems Description
Air System .......................................................... .
Electrical System ..................................................... .
Fuel System ......................................................... .
Lubrication System .................................................... .
Starting System ....................................................... .
Variable Geometry (VG) System ......................................... .
Gearbox Assembly and Components, Accessory Drive
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
General Information, Safety Precautions. Unit Conversion. and Abbreviations ........ .
General Inspection Instructions ............................................. .
General Maintenance Practices ............................................. .
General Safety Precautions and Hazards ..................................... .
Work
Package
I
WP005 00
WP004 00
WP005 10
WP005 00
WP005 10
WP005 10
WPOOS 10.
WPOOS 10
WP002 00
WP 014 00
WP005 00
WPOOS 10
WP003 00
WP004 00
WPOOS 00
WP 016 00
WP004 00
WP003 00
I
I
I
I
I
I
I
WP003 00
WP003 00
WP003 00
WP003 00
WP003 00
WP003 00
WP005 10
I
I
I
I
I
WP003
WP003
WP003
WP003
WP003
WP003
00
00
00
00
00
00
I
WP032
WP032
WP032
WP002
WP007
WP007
WP002
00
00
00
00
00
00
00
I
I
I
I
I
I
I
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 13
INDEX (Cont)
Subject
Volume
Work
Package
H
Hand Tools
Handling Equipment for Gas Turbine ........................................
Harness Segments, Thermocouple
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Testing .............................................................
Removal ............................................................
Hazards and General Safety Precautions .....................................
Heat Exchanger and Oil Line (L32119G05)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
High Power (Steady-State) Problems, Troubleshooting (Industrial) ................
High Power (Steady-State) Problems, Troubleshooting (Marine) ..................
High-Pressure Turbine Section Description ...................................
High Vibrations, Troubleshooting (Industrial) .................................
High Vibrations, Troubleshooting (Marine) ...................................
Hose Assemblies, Fuel Injector (Marine) (L32119GO I /-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Hose Assemblies, Variable Geometry (VG) Actuator
Installation ..........................................................
Removal ............................................................
Hose Assemblies (Lubrication System) (L32119GO I /-G02/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Hose Assemblies (Lubrication System L32119G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Hoses, Water Wash
Installation ..........................................................
Removal ............................................................
Hot Start, Abnormal Running Condition (Industrial) ............................
Hot Start. Abnormal Running Condition (Marine) ..............................
Hot Start (Starting Stall), Troubleshooting (Industrial) ..........................
.
WP 007 00
WP004 00
.
.
.
.
.
.
WP025
WP025
WP025
WP025
WP025
WP002
00
00
00
00
00
00
.
.
.
.
.
.
.
.
.
WP031
WP031
WP031
WP031
WP006
WP 006
WP003
WP006
WP 006
10
10
10
10
00
10
00
00
10
.
.
.
WP 030 10
WP 030 10
WP 030 10
.
.
WP028 00
WP028 00
.
.
.
.
.
WP031
WP 031
WP031
WP 031
WP031
00
00
00
00
00
.
.
.
.
.
WP031
WP 031
WP031
WP031
WP031
10
10
10
10
10
.
.
.
.
.
WP022 00
WP022 00
WP005 00
WP 005 10
WP 006 00
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
001 00
GEK 99441
Page 14
31 May 2002
INDEX (Cant)
Volume
Subject
Hot Start (Starting Stall). Troubleshooting (Marine) ............................ .
Hydraulic Starter
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.............................................................
Idle Speed Problems. Troubleshooting (Industrial) ............................. .
Idle Speed Problems. Troubleshooting (Marine) ............................... .
Igniter Plugs and Bushings
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Ignition Exciter
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Ignition Leads
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Repair .............................................................. .
Ignition System Components
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Repair .............................................................. .
Ignition System Test ..................................................... .
Injector Hose Assemblies, Fuel (Marine) (L32119G01/-G03/-G04
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Injectors, Fuel (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Injectors, Fuel (Marine) (L32119G05/-G06)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Work
Package
WP 006 10
I
I
WP033 00
WP033 00
I
I
WP006 00
WP 006 10
I
I
WP023 00
WP023 00
WP023 00
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
WP023
WP023
WP023
WP023
00
00
00
00
WP023
WP023
WP023
WP023
WP023
00
00
00
00
00
WP023
WP023
WP023
WP023
WP023
WP 018
00
00
00
00
00
00
WP 030 10
WP030 10
WP 030 10
WP03000
WP030 00
WP030 00
WP030 00
WP030 20
WP030 20
WP030 20
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 15
INDEX (Cant)
Volume
Subject
Inlet Guide Vanes (IGV) Actuator Arms
Inspection ...........................................................
Replacement .........................................................
Inlet Guide Vanes (IGV) Actuator Ring
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Inlet Inspection, Gas Turbine ..............................................
Inspection and Prestart Checks (Industrial) ...................................
Inspection, Borescope
Combustion Liner .....................................................
Compressor Casing ....................................................
Compressor Rotor Blades ...............................................
Fuel Injectors ........................................................
Inlet Guide Vanes .....................................................
Post Bore scope Inspection Procedures .....................................
Stage I High-Pressure Turbine (HPT) Rotor Blades ..........................
Stage I Turbine Nozzle ................................................
Stages I and 2 High-Pressure Turbine (HPT) Rotor Blades ....................
Stages 3 through 5 Low Pressure Turbine (LPT) Rotor Blades ..................
Stationary Vanes ......................................................
Variable Vanes .......................................................
Inspection, Centervent Tube ...............................................
Inspection, Extent and Methods ............................................
Inspection, Inlet, Gas Turbine ..............................................
Inspection instructions. General ............................................
Inspection Terms. Definitions ..............................................
Inspection Instructions, General ............................................
Installation of Gas Turbine into Shipping Container ............................
Instrumentation Requirements, Troubleshooting (Industrial) ......................
Instrumentation Requirements. Troubleshooting (Marine) ........................
Introduction ............................................................
Work
Package
.
.
WP029 00
WP029 00
.
.
.
.
.
WP029 00
WP029 00
WP029 00
WP009 00
WPOOS 00
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
WPOIOOO
WP 010 00
WP 010 00
WP 010 00
WP01000
WP 01000
WP01000
WPOIOOO
WPOIOOO
WP 010 00
WPOIOOO
WP 010 00
WPOII 00
WP007 00
WP009 00
WP 007 00
WP007 00
WP007 00
WP004 00
WP00600
WP00610
WP002 00
I
L
Leads. Ignition
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Repair ..............................................................
Levels of Maintenance ...................................................
Linkage Actuation System Components. Variable Geometry (VG)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
.
.
.
.
.
.
WP023
WP023
WP023
WP023
WP002
WP002
.
.
.
WP028 00
WP028 00
WP028 00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00
00
00
00
00
00
GEK 99441
001 00
31 May 2002
Page 16
INDEX (Cont)
Subject
Volume
Linkage Assemblies. Actuator System ....................................... .
Adjustment .......................................................... .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Lock-Wiring Practices .................................................... .
Lube and Scavenge Pump and Components (L32119GOI!-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Servicing ............................................................ .
Lube and Scavenge Pump Components (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Lube Filter Servicing ..................................................... .
Lubricants ............................................................. .
Lubrication System ...................................................... .
Gas Turbine Systems Description ........................................ .
Problems, Troubleshooting (Industrial) .................................... .
Problems. Troubleshooting (Marine) ...................................... .
Servicing ............................................................ .
Lubrication System Components (L321 19GO I/-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Servicing ............................................................ .
Lubrication System Components (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Servicing ............................................................ .
I
I
I
I
Work
Package
WP029 00
WP029 00
WP029 00
WP029 00
WP007 00
I
WP 031
WP031
WP031
WP031
WP 019
00
00
00
00
00
I
I
I
I
I
I
WP031
WP 031
WP 031
WP 031
WP 019
WP007
10
10
10
10
00
00
I
I
I
I
WP003 00
WP00600
WP 006 10
WP 019 00
I
WP031 00
WP 031 00
WP031 00
WP031 00
WPOI9 00
I
I
I
I
I
I
I
I
I
I
WP031
WP031
WP031
WP031
WP 019
10
10
10
10
00
M
Main Fuel Pump (Marine) (L32119GOI/-G03/-G04)
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
I
WP030 10
WP030 10
WP030 10
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 17
INDEX (Cant)
Subject
Volume
Main Fuel Pump (Marine) (L32119G05/-G06)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Maintenance
Levels ..............................................................
Periodic Inspections. and Maintenance ....................................
Standard Practices ....................................................
Techniques ..........................................................
Maintenance and Storage of Gas Turbine While in Shipping Container .............
Maintenance Practices, Standard ............................................
Manifold Assembly (Fuel System- Natural Gas) (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Manifold Assemblies. Fuel (Maine) (L32119G05/-G06)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Manual, Arrangement ....................................................
Manual Changes ........................................................
Materials, Consumable ...................................................
Methods and Extent of Inspection ...........................................
Motoring Procedure (Marine) ..............................................
Work
Package
.
.
.
WP03020
WP030 20
WP03020
.
.
.
.
.
.
WP002 00
WP008 00
WP007 00
WP007 00
WP 004 00
WP 007 00
.
.
.
.
WP03000
WP03000
.
.
.
.
.
.
.
.
l
wPmooo
WP030 00
I
I
WP 030 20
WP030 20
WP030 20
WP002 00
WP002 00
WP002 00
WP007 00
WP 005 10
N
No Start (NoN I Indication), Troubleshooting (Industrial) .......................
No Start (No XN2 Indication). Troubleshooting (Marine) ........................
No Start (With NI Indication). Troubleshooting (Industrial) ......................
No Start (With XN2 Indication), Troubleshooting (Marine) ......................
Non-Positioning Type Fittings Installation Practices ............................
Normal Operating Ranges and Limits (Industrial) ..............................
Normal Operating Ranges and Limits (Marine) ................................
Notes, Warnings. and Cautions .............................................
Nozzles, Spray. Water Wash
Installation ..........................................................
Removal ............................................................
.
.
.
.
.
.
.
.
I
I
WP006 00
WP 006 10
WP006 00
WP 006 10
WP007 00
WP005 00
WP 005 10
WP002 00
.
.
WP022 00
WP022 00
Offset Extension (Crowfoot)
Computations ........................................................ .
Wrench ............................................................. .
Oil Analysis Interpretation ................................................ .
WP007 00
WP007 00
WP 015 00
0
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
001 00
GEK 99441
31 May 2002
Page 18
INDEX (Cont)
Subject
Volume
Oil Sampling Procedure ..................................................
Oil Analysis Program (SOAP). Spectrometric .................................
Oil Line (L32119G05)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Oil Pressure (Abnormal Running Condition) (Industrial) .........................
Oil Pressure (Abnormal Running Condition) (Marine) ..........................
Oil Supply Tubes (L32119GO I /-G02/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Oil Supply Tubes (L321 19G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ..... ·.......................................................
Operating Limits and Ranges. Normal (Industrial) ..............................
Operating Limits and Ranges, Normal (Marine) ...............................
Operating Procedures and Limits (Industrial) ..................................
Operating Procedures and Limits (Marine) ....................................
Operation. Basic Gas Turbine ..............................................
Operation. Gas Turibine (Marine) ...........................................
Operation Principles, Gas Turbine ..........................................
Orientation and Points of Reference .........................................
Organization of Inspection Data ............................................
Overspeed. Abnormal Running Condition (Industrial) ...........................
Overspeed. Abnormal Running Condition (Marine) .............................
Overspeed/Overtemperature. Troubleshooting (Industrial) .......................
Overspeed/Overtemperature, Troubleshooting (Marine) .........................
Overtemperature. Abnormal Running Condition (Industrial) ......................
Overtemperature. Abnormal Running Condition (Marine) ........................
Work
Package
.
.
I
I
WP 015 00
WP 015 00
.
.
.
.
.
.
I
I
I
I
I
I
WP03110
WP03110
WP031 10
WP031 10
WP005 00
WP 005 10
.
.
.
.
.
I
I
WP031
WP 031
WP 031
WP031
WP031
00
00
00
00
00
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
I
WP 031 10
WP03110
WP031 10
WP031 10
WP031 10
WP 005 00
WP 005 10
WP005 00
WP 005 10
WP 003 00
WP 005 10
WP003 00
WP002 00
WP 007 00
WP005 00
WP005 10
WP006 00
WP 006 10
WP005 00
WP 005 10
Packings (Preformed). Installation Practices ................................... .
Page Numbers, Work Package ............................................. .
Periodic Inspections and Maintenance ....................................... .
I
I
WP007 00
WP002 00
WP008 00
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
p
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 19
INDEX (Cant)
Subject
Volume
Plug. Drain
Cleaning ............................................................ .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection ........................................................... .
Installation .......................................................... .
Ren1oval ............................................................ .
Plugs and Bushings, Igniter
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Points of Reference and Orientation ......................................... .
Positioning Type Fittings Installation Practices ................................ .
Post Borescope Inspection Procedures ....................................... .
Post-Shutdown Fire. Troubleshooting (Industrial) .............................. .
Post-Shutdown Fire. Troubleshooting (Marine) ................................ .
Power Turbine Section Description .......................................... .
Power Turbine (PT) Speed Sensor Assemblies
Installation .......................................................... .
Removal ............................................................ .
Practices. Shop ......................................................... .
Precautions, Safety
General ............................................................. .
Hazards and General Safety Precautions ................................... .
Preformed Packings, Installation Practices .................................... .
Preparation of Cleaning and Rinsing Solutions ................................ .
Preservation
Bearings, Oil Wetting (Siushing) Gas Turbine ............................... .
Fuel System (Marine) .................................................. .
Gas Turbines ......................................................... .
Pressure Regulating Valve Assembly (Industrial)
Installation .......................................................... .
Removal ............................................................ .
Test ................................................................ .
Pressure Regulating Valve Assembly (Marine)
Installation .......................................................... .
Removal ............................................................ .
Test ................................................................ .
Prestart Checks (Marine) .................................................. .
Prestart Checks and Inspection (Industrial) ................................... .
Principles of Operation ................................................... .
Pump and Components. A-Sump Scavenge (L32119GOI/-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Servicing ............................................................ .
I
I
I
I
I
.I
Work
Package
WP013
WP 013
WPOI3
WP 013
WP 013
00
00
00
00
00
WP023 00
WP023 00
WP023 00
WP002 00
WP007 00
WP 010 00
WP006 00
WP006 10
WP003 00
WP027 00
WP027 00
WP007 00
I
I
I
WP002 00
WP002 00
WP007 00
WPOI7 00
I
WP 014 00
WP 014 00
WP 014 00
I
I
WP021 00
WP 021 00
WP021 00
I
I
I
I
I
I
WP021
WP021
WP 021
WP005
WP005
WP003
10
10
10
10
00
00
WP031
WP031
WP031
WP031
WP019
00
00
00
00
00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
001 00
GEK 99441
Page 20
31 May 2002
INDEX (Cont)
Subject
Volume
Pump and Components. A-Sump Scavenge (L32119G05)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Servicing ............................................................
Pump and Components. Lube and Scavenge (L32119GO I/-G02/-G03/-G04)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Servicing ............................................................
Pump and Components, Lube and Scavenge (L32119G05/-G06)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Servicing ............................................................
Pump. Main Fuel (Marine) (L32119GOI/-G03/-G04)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Pump, Main Fuel (Marine) (L32119G05/-G06)
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Purpose and Scope of Technical Manual
.
.
.
.
.
I
I
I
I
I
.
.
.
.
.
I
.
.
.
.
.
I
I
I
I
I
I
I
I
I
Work
Package
WP031
WP031
WP031
WP031
WP 019
10
10
10
10
00
WP031
WP 031
WP 031
WP031
WP 019
00
00
00
00
00
WP 031
WP031
WP 031
WP031
WPOI9
10
10
10
10
00
.
.
.
I
I
I
WP030 10
WP030 10
WP 030 10
.
.
.
I
I
I
I
WP030 20
WP030 20
WP030 20
WP002 00
.
.
.
.
I
I
WP032
WP032
WPOOS
WP 005
00
00
00
10
.
.
.
.
.
I
WP 021
WP 021
WP 021
WP021
WP021
10
10
10
10
10
R
Radial Driveshaft
Installation ..........................................................
Removal ............................................................
Ranges and Limits. Operating (Industrial) ....................................
Ranges and Limits, Operating (Marine) ......................................
Regulator Valve Aft Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
I
I
I
I
I
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 21
INDEX (Cant)
Volume
Subject
Regulator Valve Forward Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Removal of Gas Turbine from Shipping Container. .............................
Repair and Inspection of Shipping Container ..................................
Rig Check (Operating Condition) of Variable Stator Vanes (VSV) System ...........
Rigging (Static Condition) of Variable Stator Vanes (VSV) System ................
Ring, IGV Actuator
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Rings. Stages I through 5 Actuator
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Rinsing and Cleaning. Compressor ..........................................
Rinsing and Cleaning Solutions. Preparation ...................................
Work
Package
.
.
.
.
.
.
.
.
.
WP 021 10
WP 021 10
WP021 10
WP021 10
WP021 10
WP004 00
WP004 00
WP 012 00
WP 012 00
.
.
.
WP029 00
WP029 00
WP029 00
.
.
.
.
.
WP029
WP029
WP029
WP 017
WP 017
00
00
00
00
00
s
Safety Precautions, Abbreviations, General Information, and Unit Conversion ........ .
Scavenge Tubes (L32119GO li-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Scavenge Tubes (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Scope and Purpose of Technical Manual ..................................... .
Seal Pressurizing and B-Sump Regulating System Components (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Test ................................................................ .
WP002 00
I
I
I
I
WP031
WP031
WP 031
WP 031
WP031
00
00
00
00
00
WP031
WP031
WP031
WP031
WP031
WP002
10
10
10
10
10
00
WP021
WP021
WP021
WP021
WP 021
WP021
10
10
10
10
10
10
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
Page 22
31 May 2002
INDEX (Cant)
Volume
Subject
Seal Pressurizing System Components (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Sensor Assemblies, Power Turbine (PT) Speed
Installation .......................................................... .
Removal ............................................................ .
Sensors. Gas Generator Speed
Installation .......................................................... .
Removal ............................................................ .
Servicing, Fuel System (Marine) ........................................... .
Servicing of Fuel System When Bypass Indicator Button has Popped (Marine) ....... .
Servicing, Lubrication System
A-Sump Scavenge Pump ............................................... .
Lube and Scavenge Pump ............................................... .
Lube Filter .......................................................... .
Setup of Borescope Kit ................................................... .
Shaft, Radial Drive
Installation .......................................................... .
Removal ............................................................ .
Shipping Container. I 06C7556
Description .......................................................... .
Inspection ........................................................... .
Installation of Gas Turbine into .......................................... .
Removal of Gas Turbine from ........................................... .
Repair .............................................................. .
Shop Practices .......................................................... .
Shutdown and Starting Procedures (Industrial) ................................. .
Shutdown (Industrial) .................................................... .
Shutdown, Emergency (Industrial) .......................................... .
Shutdown Procedures, Normal (Marine) ...................................... .
Slow Acceleration to Idle or Does Not Reach Idle. Troubleshooting (Industrial) ...... .
Slow Acceleration to Idle or Does Not Reach Idle, Troubleshooting (Marine) ........ .
Special Inspection Requirements ........................................... .
Gas Turbine ......................................................... .
Spectrometric Oil Analysis Program (SOAP) ............................... .
Spectrometric Oil Analysis Program (SOAP) .................................. .
Speed Sensor Assemblies. Power Turbine (PT)
Installation .......................................................... .
Removal ............................................................ .
Speed Sensors. Gas Generator
Installation .......................................................... .
Removal ............................................................ .
Work
Package
WP 021
WP021
WP021
WP021
WP 021
00
00
00
00
00
WP027 00
WP027 00
I
WP02600
WP026 00
WP02000
WP02000
I
I
I
I
WP 019 00
WP 019 00
WP019 00
WP 010 00
I
I
WP032 00
WP032 00
I
I
I
WP004 00
WP004 00
WP004 00
I
I
I
WP004 00
I
I
I
I
I
I
I
I
I
I
WP004 00
WP007 00
WP005 00
WP005 00
WP005 00
WP005 10
WP00600
WP 006 10
WP007 00
WP016 00
WP007 00
WP 015 00
I
I
WP027 00
WP027 00
I
WP02600
WP026 00
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 23
INDEX (Cant)
Subject
Volume
Spray Nozzles. Water Wash
Installation ..........................................................
Removal ............................................................
Stage 7 Air Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stage 7 Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stage 7 Balance Piston Air Tube (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stage 7 Balance Piston Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stage 7 Regulator Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stage 7 Valve Air Tube (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Stages I through 5 Actuator Rings
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Stages I through 5 Vane Actuator Arms,
Inspection ...........................................................
Work
Package
.
.
WP 022 00
WP022 00
.
.
.
.
.
WP 021 00
WP021 00
WP 021 00
WP021 00
WP 02100
.
.
.
.
.
I
WP 021
WP021
WP 021
WP 021
WP021
10
10
10
10
10
I
WP021
WP021
WP021
WP021
WP021
00
00
00
00
00
WP 021
WP 021
WP021
WP021
WP 021
10
10
10
10
10
WP021
WP 021
WP 021
WP 021
WP021
10
10
10
10
10
WP021
WP021
WP021
WP021
WP 021
10
10
10
10
10
.
.
.
.
.
.
.
.
.
.
I
.
.
.
.
.
.
.
.
.
.
I
I
I
.
.
.
WP029 00
WP029 00
WP029 00
.
WP029 00
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 24
INDEX (Cant)
Volume
Subject
Standard Maintenance Practices
Alodine 1200 Touchup ................................................. .
Blending Procedures ................................................... .
Cold-Working ........................................................ .
Vapor Degrcasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
White-Light Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter, Hydraulic
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.............................................................
Starting and Shutdown Procedures (Industrial). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Procedure (Marine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Vane Components, Variable
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal ............................................................ .
Replacement ......................................................... .
Storage and Maintenance of Gas Turbine While in Shipping Container ............. .
Support Beam Assembly (U2119G01/-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Support Equipment ...................................................... .
Work
Package
I
I
WP007
WP007
WP007
WP007
WP007
00
00
00
00
00
I
I
I
I
I
WP033
WP033
WP005
WP 005
WP003
00.
00
00
10
00
I
I
I
WP029 00
WP029 00
WP029 00
WP029 00
WP029 00
WP004 00
I
I
I
I
I
WP023
WP023
WP023
WP023
WP002
00
00
00
00
00
WP031
WP031
WP031
WP031
WP002
WP 018
10
10
10
10
00
00
WP025
WP025
WP025
WP025
WP025
WP007
WP007
WP007
00
00
00
00
00
00
00
00
T
Tank and Tubing, Engine Oil (U2119G05)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Removal ............................................................
Technical Manual, Scope and Purpose .......................................
Test, Ignition System .....................................................
Thermocouple Harness Segments
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Testing .............................................................
Removal ............................................................
Tools, Hand ............................................................
Torque-Tightening Practices ...............................................
Torque Wrench Sizes .....................................................
.
.
.
.
.
.
I
I
I
.
.
.
.
.
.
.
.
I
I
I
I
I
I
I
I
I
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 25
INDEX (Cant)
Subject
Volume
Transducers, Vibration
Installation ..........................................................
Removal ............................................................
Troubleshooting Instructions (Industrial) .....................................
Troubleshooting Instructions (Marine) .......................................
Tube, A-Sump Pressure Valve Air Metal (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube. A-Sump Pressure Valve Air Metal (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube, Air Regulator Valve (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube. B-Sump Oil (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Ren1oval ............................................................
Tube, C-Sump Aft (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube. C-Sump Aft (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Work
Package
.
.
.
.
WP024
WP024
WP006
WP 006
00
00
00
10
.
.
.
.
.
WP021
WP 021
WP 021
WP 021
WP 021
00
00
00
00
00
.
.
.
.
.
WP 021 10
WP021 10
WP02110
WP021 10
WP021 10
.
.
.
.
.
WP 021
WP021
WP 021
WP 021
WP021
10
10
10
10
10
.
.
.
.
.
WP021
WP021
WP021
WP021
WP 021
10
10
10
10
10
.
.
.
.
.
WP021
WP 021
WP 021
WP 021
WP 021
00
00
00
00
00
.
.
.
.
.
WP 021
WP021
WP021
WP021
WP021
10
10
10
10
10
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 994.41
001 00
31 May 2002
Page 26
INDEX (Cant)
Subject
Volume
Tube. C-Sump Forward (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube, C-Sump Forward (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube, Centervent, Inspection ...............................................
Tube, Drain Separator (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube, Drain Separator (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube. Regulator Valve Aft Air (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Tube, Regulator Valve Forward Air (Marine)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
Test ................................................................
Tube. Stage 7 Air (Industrial)
Cleaning ............................................................
Inspection ...........................................................
Installation ..........................................................
Pressure-Test. ........................................................
Removal ............................................................
.
.
.
.
.
1
I
I
I
I
Work
Package
WP 021
WP021
WP 021
WP 021
WP 021
00
00
00
00
00
10
10
10
10
10
00
.
.
.
.
.
.
I
I
I
WP021
WP021
WP 021
WP 021
WP021
WPOll
.
.
.
.
.
I
I
I
I
WP 021
WP 021
WP 021
WP 021
WP 021
00
00
00
00
00
I
I
WP021
WP021
WP021
WP021
WP 021
10
10
10
10
10
I
I
I
WP 021
WP 021
WP021
WP 021
WP021
10
10
10
10
10
10
10
10
10
10
10
00
00
00
00
00
.
.
.
.
.
.
.
.
.
.
I
I
I
I
.
.
.
.
.
.
I
I
WP 021
WP 021
WP 021
WP 021
WP021
WP021
.
.
.
.
.
I
I
I
I
I
WP 021
WP 021
WP 021
WP 021
WP 021
I
I
I
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
001 00
31 May 2002
Page 27
INDEX (Cont)
Subject
Volume
Tube. Stage 7 Air (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tube. Stage 7 Balance Piston Air Tube (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tube. Stage 7 Balance Piston Air Tube (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tube, Stage 7 Regulator Air Tube (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tube, Stage 7 Valve Air (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tubes, Fuel Feed (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Tubes. Oil Supply (L32119GOI/-G02/-G03/-G04)
Cleaning ............................................................. .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
I
I
I
Work
Package
WP 021
WP021
WP021
WP021
WP021
10
10
10
10
10
WP 021
WP021
WP021
WP021
WP 021
00
00
00
00
00
WP021
WP 021
WP 021
WP 021
WP021
10
10
10
10
10
WP021
WP021
WP021
WP021
WP 021
10
10
10
10
10
WP021
WP021
WP021
WP021
WP021
10
10
10
10
10
WP030 00
WP03000
WP03000
WP03000
WP 031
WP 031
WP031
WP031
WP031
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00
00
00
00
00
001 00
GEK 99441
Page 28
31 May 2002
INDEX (Cont)
Volume
Subject
Tubes. Oil Supply (L32119G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tubes, Scavenge (L321 19GO I /-G02/-G03/-G04)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tubes, Scavenge (L321 19G05/-G06)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tubes, Seal Pressurizing and B-Sump Regulating System (Marine)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
Tubes, Seal Pressurizing System (Industrial)
Cleaning ............................................................ .
Inspection ........................................................... .
Installation .......................................................... .
Pressure-Test. ........................................................ .
Removal ............................................................ .
I
I
I
I
Work
Package
WP03110
WP031 10
WP031 10
WP031 10
WP031 10
I
WP03110
WP03100
WP 031 00
WP031 00
WP031 00
I
I
I
I
I
WP03110
WP031 10
WP03110
WP031 10
WP031 10
I
I
I
I
I
WP 021
WP021
WP021
WP021
WP 021
10
10
10
10
10
I
I
I
I
I
WP 021
WP021
WP 021
WP021
WP 021
00
00
00
00
00
I
WP002 00
I
WP 021 00
WP 021 00
WP 021 00
I
I
I
u
Unit Conversion, Abbreviations, General Informationn, and Safety Precautions, ...... .
V
Valve Assembly, Pressure Regulating (Industrial)
Installation .......................................................... .
Removal ............................................................ .
Test ................................. ···· .. ··························
Valve Assembly, Pressure Regulating (Marine)
Installation .......................................................... .
Removal ............................................................ .
Test ................................. · ..... ··························
WP 021 10
WP 021 10
WP 021 10
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
001 00
GEK 99441
Page 29
31 May 2002
INDEX (Cant)
Volume
Subject
Valve, B-Sump Regulator (Marine)
Installation .......................................................... .
Removal ............................................................ .
Test ............................................... ··················
Vane Actuator Arms, Stages I through 5
Inspection ........................................................... .
Vane Components. Variable Stator
Adjustment .......................................................... .
Inspection ........................................................... .
Installation .......................................................... .
Ren1oval ............................................................ .
Replacement ......................................................... .
Vapor Degreasing ....................................................... .
Variable Geometry System Description ...................................... .
Variable Geometry (VG) Actuator Hose Assemblies
Installation .......................................................... .
Removal ............................................................ .
Variable Geometry (VG) Actuators.
Inspection ........................................................... .
Installation .......................................................... .
Removal .....· ....................................................... .
Replacement of Nipples. Rod-End Bearing. Reducer. and Plug on VG Actuator .... .
Variable Geometry (VG) Control Assembly
Adjustment .......................................................... .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Repair .............................................................. .
Variable Geometry (VG) Feedback Cable
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Variable Geometry (VG) Linkage Actuation System Components,
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Variable Geometry (VG) System Description .................................. .
Variable Stator Vane Components
Adjustment .......................................................... .
Inspection ........................................................... .
Installation .......................................................... .
Removal ............................................................ .
Replacement ......................................................... .
Work
Package
WP 021 10
WP021 10
WP021 10
WP029 00
WP029
WP029
WP029
WP029
WP029
WP007
WP003
00
00
00
00
00
00
00
WP028 00
WP028 00
WP028
WP028
WP028
WP028
I
00
00
00
00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
WP028 00
I
wPomoo
WP029
WP029
WP029
WP029
WP029
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00
00
00
00
00
GEK 99441
001 00
31 May 2002
Page 30
INDEX (Cont)
Subject
Volume
Variable Stator Vanes (VSV) System
Inspection ...........................................................
Rig Check (Operating Condition) ........................................
Rigging (Static Condition) ..............................................
Vibration Transducers
Installation ..........................................................
Removal ............................................................
Vibrations (Abnormal Running Condition) (Industrial) ..........................
Vibrations (Abnormal Running Condition) (Marine) ............................
Work
Package
.
.
.
WP 012 00
WP 012 00
WP 012 00
.
.
.
.
WP024
WP024
WP005
WP 005
00
00
00
10
w
Warnings. Cautions. and Notes .............................................
Water Wash Hoses
Installation ..........................................................
Removal ............................................................
Water Wash Hoses and Spray Nozzles
Installation ..........................................................
Removal ............................................................
Water Wash Spray Nozzles
Installation ..........................................................
Removal ............................................................
White-Light Inspection ...................................................
Work Package Change/Revised Numbers .....................................
Work Package Page Numbers ..............................................
Wrench Computations. Offset Extension (Crowfoot) ............................
Wrench. Offset Extension (Crowfoot) .......................................
Wrench Sizes. Torque ....................................................
.
I
WP002 00
.
.
I
I
WP022 00
WP022 00
.
.
I
WP022 00
WP022 00
.
.
.
.
.
.
.
.
I
I
WP022 00
WP022 00
WP007 00
WP002 00
WP 002 00
WP007 00
WP007 00
WP007 00
I
I
I
I
I
I
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
Page 1 of 16
31 May 2002
LMSOO GAS TURBINE
Operating Instructions and On-Site Maintenance
INTRODUCTION
GENERAL INFORMATION, SAFETY PRECAUTIONS, AND ABBREVIATIONS
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Abbreviations ...................................................................... .
General Information ................................................................. .
Arrangement of Technical Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changes to Technical Manual. ................................................. ·. . . . . . .
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Turbine Points of Reference and Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Levels of Maintenance ............................................................ .
Purpose and Scope of Technical Manual ............................................... .
Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings. Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Package Change/Revised Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Package Page Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General..........................................................................
Hazards and General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
Page No.
10
2
2
5
5
4
5
2
4
4
5
5
7
13
GENERAL INFORMATION.
a.
Purpose and Scope of Technical Manual.
(I) This manual provides instructions for organizational level maintenance (installation and removaL operation, troubleshooting. and preventive maintenance) for the LM500 Gas Turbine models L32119G02 (Industrial) and
L32119GO I/-G03/-G04/-G05/-G06 (Marine).
(2) These gas turbines were designed by GE Aircraft Engines. Marine and Industrial Engine Projects Department. Cincinnati. Ohio 45215 USA. These gas turbines are manufactured by GE Aircraft Engines, Military Engine Projects
Division. 1000 Western Avenue. Lynn. Massachusetts 01910 USA.
b.
Levels of Maintenance.
(I) Level I maintenance tasks consist of all work done on the exterior of an installed gas turbine: scheduled
inspections. compressor cleaning (water wash). and replacement of the gas turbine. Level I maintenance tasks are provided in
WP 003 00 through WP 020 00.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
002 00
31 May 2002
Page2
(2) Level 2 maintenance tasks consist of removaL cleaning. inspection. repair. test and installation of one or
more major gas turbine components. Level 2 maintenance tasks are provided in WP 021 00 through WP 032 00.
c.
Arrangement of Technical Manual.
(I)
This manual is arranged in Work Package format.
(2) Pages, paragraphs. tables. and figures have been assigned successive Arabic numerals. starting from I, in
each work package.
(3)
Subparagraphs have been assigned lower-case letters (a .. b .. c., etc.). and are further subdivided by Arabic
numerals in parentheses: (I), (2 ), (3 ), etc.
(4)
d.
Further subdivisions are in lower-case letters in parentheses: (a). (b). (c). etc.
Warnings, Cautions, and Notes.
Warnings. Cautions. and Notes will be found throughout this manual. It is important that the significance of each
is thoroughly understood by personnel using this manual. Their definitions are:
(I)
WARNING: indicates a procedure or practice which. if not followed correctly. could result in personal
hazard or injury.
(2) CAUTION: indicates a procedure or practice which. if not strictly observed. could result in damage or
destruction of equipment.
(3)
e.
NOTE: highlights an essential procedure to assure correct maintenance.
Changes to Technical Manual.
(I)
Change Symbol. Changes (including addition of new technical data to text, tables. and illustrations) are
indicated by the use of vertical line (see figure I). Previous change symbols will be deleted when a page"is subsequently
changed, so that the new change symbols show the latest technical change.
(2) Changes to Text. Changes arc indicated by a vertical line at the margin of the page, along the changed text
(see figure I). When paragraphs, steps. or tables are deleted. the word "Deleted'' will appear next to the paragraph/step/table
number.
(3)
Changes to Illustrations, Diagrams. and Schematics. Changes to illustrations. diagrams, and schematics
are also indicated by a vertical line (see figure I). When index numbers are deleted, the word "Deleted'' will appear next to the
index number. (Illustrations represent the gas turbine configuration at the time of inclusion in this technical manual. They may
not be changed to represent all and/or the latest gas turbine configurations. They are to be used as an aid in doing maintenance
tasks in accordance with the procedures in this manual.)
(4) Page Changes. Insert the latest changed pages and discard the superseded pages. Pages that have changed
are designated by the change number and date at the top of each atlected page. Refer to the List of Effective Pages in the front
of each Work Package to determine the latest changed pages including added and/or deleted pages.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
Page3
31 May 2002
/
I
-- .
(I)
11/L __ •L-
•• ''CII
""'
.,.ti·JC· •
Wlltn ... laic
r
r---'---foa.1 .._, rain, or ,.':; there la
(2)
(J)
CHANGE
BARS
w
m,
RIGGING PIN
21C1296
f>.L\GNMENI
PLf>.lt
is
ia installed.
.
ll.8efj
ore •tvtin" clo rhe
(I)
I'Oior to lll.llte litre
rurarc the eo
lu rocare.
lhc m ·
(2) Use 1rou
line unw I'Oior ia li nd Jtc.arer llnita to
IO I'Oiate_
W.1f111
rocor ia li
"'"l'elsclr
NOTE
CHANGE SYMBOLS ARE NOT USED FOR:
-dor"""
'l'emely hiJ•
•
1101
.111Cf oil
•INTRODUCTORY MATERIAL, INDEXES, AND TABULAR DATA
oiJCOfrtej .....
WHERE THE CHANGE CANNOT BE IDENTIFIED
• BLANK SPACE RESULTING FROM THE DELETION OF TEXT,
ILLUSTRATION, OR TABLE
• CORRECTION OF MINOR INACCURACIES, SUCH AS SPELLING,
PUNCTUATION, RELOCATION OF MATERIAL, ETC., UNLESS
SUCH CORRECTION CHANGES THE MEANING OF INSTRUCTIONS,
INFORMATION, AND PROCEDURES
Figure I.
Change Symhols
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
31 May 2002
Page 4
f.
Work Package Page Numbers. The page count at the top of each work package title page indicates the total
number of pages in the work package. including A and B pages. Therefore. the page number on the last page may not agree
with the page count on the title page. For example. if the pages in WP 001 00 arc numbered I. 2, 2A. 2B. 3. 4. 5/6. the title
page will read "Page I on\".
g.
Work Package Change/Revised Numbers.
(I) Revised Work Packages (WP) have the issue date only in the upper left-hand corner of Title Page and each
page within the WP. At the time of subsequent Changes. the Change Date and Change Number are placed in the upper lefthand corner of Title Page and on each Change Page in the WP, while the Original or Revised pages remain the same. having
Change Bars and Revision Date. The backup page to a Change Page also continues to carry its Change/Revised Date or Original Date and Change Bars if applicable.
(2) The status of each page can be verified by the "0" or Change Number listed in the Change No. column in
the List of Effective Work Package Pages on the WP Title Page. Revised pages are identified by the "0". Change Pages are
identified by the Change Number and Change Date appearing in the upper left-hand corner of the Change Page. This number
is also the same as the Change Number on the Title Page of the manual at the time the Change Page is issued.
h. Gas Turbine Points of Reference and Orientation. Unless otherwise specified. all references to left. right. forward. aft. and clock positions apply when viewing the gas turbine from the aft end (exhaust end) looking towards the forward
end (see figure 2).
...
AFT
FORWARD
12
DIRECTION
9 O'CLOCK
OF
ROTATION 6 O'CLOCK
7LH-008
Figure 2.
Gas Turbine Points of Reference and Orientation
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
PageS
31 May 2002
i.
Support Equipment, Consumable Materials, and Expendables. At the beginning of each work package there
may be a table that lists the support equipment and the consumable materials that are required to do the maintenance tasks in
the work package. The support equipment and the consumable materials are defined as follows:
(I)
Support Equipment: special tools that are needed to remove, clean. inspect. repair. assemble. install. or test
gas turbine components to make them operational.
(2) Consumable Materials: items that are not listed in the Illustrated Parts Breakdown (GEK 99441, Volume
11), or that cannot be reused. are considered consumable materials. Included are items such as lock wire, greases, and solvents.
(3)
Expendables: some items that are listed in the Illustrated Parts Breakdown (GEK 99441. Volume Il) are
not reusable. These items include preformed packings. tabwashers. and cotter pins.
2.
SAFETY PRECAUTIONS.
a.
General. The intent of this technical manual is to provide procedures and processes for accomplishing the safe
operation and maintenance tasks of the gas turbine. Therefore, it is important that the Warnings and Cautions be thoroughly
understood and observed by the users of the manual. Any changes, additions. or suggestions that are deemed necessary for the
proper operation. maintenance. and safety improvements of the gas turbine should be submitted using the Publication Change
Request Form (see figure 3) to:
Manager, Customer Service and Product Support
Marine and Industrial Engine Projects Department
GE Aircraft Engines
Mail DropS 156
Cincinnati. OH 45215
USA
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
002 00
31 May 2002
Page6
PUBLICATION CHANGE REQUEST
PCR No.
GE Marine Engines
D
LM6000
0
Industrial
0
LMSOOO
0
REQUEST FOR
D
LM2500
Mail to:
0
International Marine
0
D
LM1600
0
0
LMSOO
Shipyard
GE Marine Engines
Marine Service and Factory Technical Support
Mail Drop S-156
One Neumann Way
PO Box 156301
Cincinnati, Ohio 45215-6301, USA
ATIN: Documentation Programs
Manual
other
Originator
Address
Date
Document I.D. No.
Page No.
Para.
Fig No.
Table No.
Phone No.
Subject of Change
Specific Instructions
Reference Documents
FORGE USE:
GE Manual Specialist
Closed Date
Send To
Closed By
Response
CC:
'
1172535-00-A2A
Figure 3.
Publication Change Request Form
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
Page?
31 May 2002
b. Hazards and General Safety Precautions. The following are general safety precautions that are not related to any
specific procedures: therefore. they do not appear elsewhere in this manual. Personnel must understand and apply these precautions during any phase of operation and maintenance of the gas turbine.
(I)
Health Hazards:
I WARNING I
•
•
•
•
•
(2)
Use all cleaning solvents. fuels, oils. adhesives and
epoxys, 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 damage to the
body's nervous system and possible death, if breathed
frequently.
Avoid frequent or prolonged exposure to the skin.
Wash thoroughly with soap and warm water as soon
as possible after using these materials.
Take special precautions to avoid getting materials in
the eyes. If exposed, rinse the eyes in an eye bath
fountain immediately and 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 adhesives 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 separation procedures.
Fire Hazards:
I WARNING I
•
•
•
Keep all cleaning solvents. oils. esters and adhesives
away from open flame space heaters. exposed element
electric heaters, sparks, or flame. Do not smoke when
using, or when in the vicinity of flammable materials.
or in areas where flammables are stored.
Provide adequate ventilation to avoid concentrations
of potentially explosive fumes or vapors.
Provide approved containers for bulk storage of flammable materials, and for dispensers in the working
areas. Keep all containers tightly closed when not in
use.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
002 00
31 May 2002
(3)
Page 8
Procedural Hazards:
I WARNING I
•
•
•
•
•
•
•
(4)
Observe all specified and logical safety practices
when doing maintenance on the gas turbine.
Wear safety glasses or other appropriate eye protection at all times.
Do not allow lockwire or lockwire clippings to fly
from the cutter during removal or installation of
lock wire.
Do not use fingers as guides when installing parts or
when checking alignment of holes.
Use only the correct tools and fixtures. and use them
as recommended.
Avoid shortcuts. such as using fewer. shorter, or the
incorrect quantity of attaching bolts.
Read all warnings contained in this manual to avoid
injury to personnel or damage to gas turbine parts.
Tooling Hazards:
I WARNING I
•
•
Improperly maintained tools and support equipment
can he dangerous to personnel and can damage gas
turbine parts. Observe the recommended inspections
and maintenance schedules of tools.
Use tools only for the purpose for which they were
designed, and avoid abuse. Be constantly alert for
damaged or unauthorized tools and support equipment. and initiate appropriate corrective action for
repair immediately.
I WARNING I
When using equipment provided or associated with high
frequency power generators, he sure that all components are
adequately isolated from noninvolved personneL and he
sure they are insulated to prevent serious injury to the operator. Be sure the generator power is off when connecting or
positioning connectors and cables, and when adjusting the
heater elements.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
Page9
31 May 2002
CAUTION
All gas turbine components have been manufactured using
the U.S. (English) measurement units. Use of substitute
metric-size components is not recommended. and will void
warranty for interfacing parts. Metric tools should he used
with suitable adapters to interface with English-size tools.
Limits, fits, and clearance measurements may be converted
to either the English or the metric units.
(5)
Operating Hazards:
I WARNING I
•
•
•
•
•
•
The external surfaces of the gas turbine are not insulated. Adequate precautions should be taken to prevent operating personnel from inadvertent contact
with the hot surfaces.
The gas turbine is a source of considerable noise. It
will be necessary for personnel working in the gas turbine compartment to wear ear protection when the gas
turbine is operating.
The gas generator is a high-speed machine. In the
remote event of parts failure, the casing of the gas
generator would contain the compressor blades and
turbine blades, but might not contain major failures of
compressor or turbine disks. Operating personnel
should not be permanently stationed in. or near, the
plane of the rotating parts.
The rotating parts of the starter operate at very high
speeds. In the remote event of parts failure, personnel
should not be stationed in the plane of the starter during the starting cycle.
The low pressure and the high velocity created by the
gas generator compressor can draw objects and personnel into the inlet of the gas generator. The use of
an inlet screen and other protective devices is recommended.
Fire protection equipment must he available at all
times.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
002 00
Page 10
31 May 2002
I WARNING I
When opening the gas turbine enclosure for inspection, or
maintenance, the following safety precautions must be
observed:
The gas turbine must be shut down. or limited to idle
speed.
The fire extinguishing system must be made inactive .
Halon can cause suffocation. if accidentally
discharged.
Avoid contact with hot parts: wear thermally insulated
gloves as necessary.
•
Ear protection must be worn if gas turbine is
operating.
•
When doing 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 prevent
activation. Tag the operating controls of the gas turbine DO NOT OPERATE to prevent starting during a
shutdown condition.
•
•
•
c.
The maintenance of the gas turbine requires that inspection checks be made periodically. The inspection
requirements and limits throughout this manual are based on operation within specified limits. In addition to the regular
inspections, there are those necessary when the gas turbine has been operated outside of the specified limits, for example, offschedule variable geometry operation. overspeed, or overtemperature. There are also specific inspections necessary for gas
turbines exposed to abnormal conditions. These may include, for example. failures with significant damage and other abnormal exposure such as installation fire or mishap during transportation, handling. or storage. This manual includes routine
inspection requirements to be accomplished for preventative maintenance and for troubleshooting. It also includes criteria for
determining if special instructions are necessary because of exposure to abnormal conditions.
3. ABBREVIATIONS. The abbreviations that are used throughout this manual to describe limits. settings. and commonly
used terms are listed in table I.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
31 May 2002
Page 11
TABLE 1.
Abbreviation
Definition
ABBREVIATIONS
Abbreviation
Definition
ac
Alternating Current
LPT
Low Pressure Turbine
AGB
Accessory Gearbox
M
Meter
Btu/lb
British Thermal Units per
Pound
mm
Millimeter
Nl
cc
Cubic Centimeter
CIT
Compressor Inlet
Temperature
Compressor Gas Generator Rotor Speed (rpm)
(Industrial Only)
N2
Power Turbine Shaft
Speed (rpm) (Industrial
Only)
N•m
Newton Meters
OAT
Outside Air Temperature
OD
Outside Diameter
t.P
Di1ferential Pressure
P4.8
Power Turbine Inlet
Total Pressure
pph
Pounds per Hour
pp m
Parts per Million
PS or PS3
Compressor Discharge
Static Pressure
ps1
Pounds per Square Inch
psia
Pounds per Square Inch
Absolute
psid
Pounds per Square Inch
Differential
ps1g
Pounds per Square Inch
Gage
cm
Centimeter
Cont
Continued
Dia
Diameter
FOD
Foreign Object Damage
GG
Gas Generator
gpm
Gallons per Minute
HMWS
Hazardous Material
Warning Section
hp
Horsepower
HPT
High-Pressure Turbine or
Gas Generator Turbine
Hz
Cycles per Second (Hertz)
ID
Inside Diameter
IGV
Inlet Guide Vane
k<>
Kilogram
kg/hr
Kilograms per Hour
kPa
Kilopascals
Jb
Pounds
PT
Power Turbine
lb/hr
Pounds per Hour
PT4.8
lb ft
Pound Feet
Power Turbine Inlet
Pressure
lb in.
Pound Inches
PTO
Power Takeoff
LHV
Low Heating Value
Qty
Quantity
Ipm
Liters per Minute
rpm
Revolutions per Minute
"'
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
31 May 2002
Page 12
TABLE 1.
Abbreviation
ABBREVIATIONS (Cont)
Definition
Abbreviation
Definition
SI
System Internationale
vsv
Variable Stator Vanes
SOAP
Spectrometric Oil
Analysis Program
Wf
Fuel Flow
WP
Work Package
Tl.5
Compressor Inlet
Temperature
XN2
T4.8
Power Turbine Inlet Total
Temperature
Compressor Gas Generator Rotor Speed (rpm)
(Marine Only)
XN2R
V
Volt
VA
Volt-Ampere
Gas Generator Corrected
Rotor Spec (rpm)
(Marine Only)
Vac
Alternating-Current Volts
XNSD
V de
Direct-Current Volts
Power Turbine Shaft
Speed (rpm)
(Marine Only)
VG
Variable Geometry
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
Page 13
31 May 2002
4. UNIT CONVERSION. This technical manual utilizes U.S. (English) units of measurement as the primary values. The
metric, or SI (Systems Internationale) units are expressed in parentheses following the English units. In most cases the SI units
are direct mathematical conversions and may be rounded off at the user's discretion. Examples where the SI units may not be
rounded off are those used for dimensional checks. rigging adjustments, runouts. etc. Tables 2. 3, and lists the conversion
factors.
CONVERSION FACTORS
TABLE 2.
to
Multiply by
centimeters
inches
0.3937
inches
inches
inches
inches
inches
inches
centimeters
feet
meters
m1crons
millimeters
yards
2.540
0.08333
0.02540
25.400
25.400
0.02778
meters
meters
feet
yards
3.2809
1.0936
microns
m1crons
inches
meters
0.0000394
0.000001
To convert from
LENGTH
PRESSURE
2
k/m
e
lb/ft
lb/in. 2 (psi)
kg/cm-
0.0703
lb/in. 2(psi)
kilopascals (kPa)
6.8948
.
ounces per m:
0.5780
2
0.2048
')
DENSITY
grams per cm 3
.
ounces per m.·
kilograms per m
pounds per ft 3
3
1.730
3
0.06243
grams per cm
3
pounds per ft
kilograms per m3
16.019
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
002 00
31 May 2002
Page 14
TABLE 2.
To convert from
CONVERSION FACTORS (Cont)
to
Multiply by
cubic centimeters
cubic inches
0.06102
cubic
cubic
cubic
cubic
cubic
cubic
cubic centimcters
cubic feet
cubic meters
liters
gallons
quarts
16.39
0.0005787
0.00001639
0.0164
0.004329
0.01732
gallons
gallons
gallons
gallons
cubic inches
cubic meters
liters
quarts
231.0
().()03785
3.785
4.0
pints
pints
liters
quarts
0.4732
0.50
ounces
milliliters (cc)
29.57353
quarts
quarts
liters
pints
0.9464
2.0
grams
grams
grams
kilograms
ounces
pounds
0.001
0.03527
0.002205
kilograms
kilograms
ounces
pounds
55.274
2.2046
ounces
ounces
grams
kilograms
28.35
0.02835
pounds
pounds
pounds
grams
kilograms
ounces
453.6
0.4536
16.0
newton-meter (N•m)
newton-meter (N•m)
1.356
0.113
VOLUME
inches
inches
inches
inches
inches
inches
WEIGHT
TORQUE
pound foot (lb ft)
pound inch (lb in.)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
002 00
31 May 2002
Page 15
TABLE 3.
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 32oF, when selected from the center column, shows a corresponding temperature of ooc in
the left column. A temperature of ooc, when selected from the center column, shows a corresponding temperature of 32°F
in the right column.
Temperature Conversion Formulas
Temperature (°C) =(Temperature oF- 32) +1.8
Temperature (°F) = (1.8 X Temperature °C) + 32
-60 to 60
oc
-51
-46
-40
-34
-29
-23
-17.8
-17.2
-16.7
-16.1
-15.6
-15.0
-14.4
-13.9
-13.3
-12.8
-12.2
-11.7
-11.1
-10.6
-10.0
-9.4
-8.9
-8.3
-7.8
-7.2
-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0.0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
61 to 350
oF
-60
-50
-40
-30
-20
-10
0
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
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
-76
-58
-40
-22
-4
14
32
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
oc
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1
21.7
22.2
22.8
23.3
23.9
24.4
25.0
25.6
26.1
26.7
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
43
49
54
60
66
71
77
82
88
93
99
104
110
116
121
127
132
138
143
149
154
160
166
171
177
61
62
83
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360 to 1050
OF
oc
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
230
248
266
284
302
320
338
356
374
392
410
428
446
464
482
500
518
536
554
572
590
608
626
644
662
182
188
193
199
204
210
216
221
227
232
238
243
249
254
260
266
271
277
282
288
293
299
304
310
316
321
327
332
338
343
349
354
360
366
371
377
382
388
393
399
404
410
416
421
427
432
438
443
449
454
460
466
471
477
482
488
493
499
504
510
516
521
527
532
538
543
549
554
560
566
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
750
760
770
780
790
800
810
820
830
840
850
860
870
880
890
900
910
920
930
940
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060 to 1750
oF
oc
680
698
716
734
752
770
788
806
824
842
860
878
896
914
932
950
968
986
1004
1022
1040
1058
1076
1094
1112
1130
1148
1166
1184
1202
1220
1238
1256
1274
1292
1310
1328
1346
1364
1382
1400
1418
1436
1454
1472
1490
1508
1526
1544
1562
1580
1598
1616
1634
1652
1670
1688
1706
1724
1742
1760
1778
1796
1814
1832
1850
1868
1886
1904
1922
571
577
582
588
593
599
604
610
616
621
627
632
638
643
649
654
660
666
671
677
682
688
693
699
704
710
716
721
727
732
738
743
749
754
760
766
771
777
782
788
793
799
804
810
816
821
827
832
838
843
849
854
860
866
871
877
882
888
893
899
904
910
916
921
927
932
938
943
949
954
OF
1060
1070
1080
1090
1100
1110
1120
1130
1140
1150
1160
1170
1180
1190
1200
1210
1220
1230
1240
1250
1260
1270
1280
1290
1300
1310
1320
1330
1340
1350
1360
1370
1380
1390
1400
1410
1420
1430
1440
1450
1460
1470
1480
1490
1500
1510
1520
1530
1540
1550
1560
1570
1580
1590
1600
1610
1620
1630
1640
1650
1660
1670
1680
1690
1700
1710
1720
1730
1740
1750
1940
1958
1976
1994
2012
2030
2048
2066
2084
2102
2120
2138
2156
2174
2192
2210
2228
2246
2264
2282
2300
2318
2336
2354
2372
2390
2408
2426
2444
2462
2480
2498
2516
2534
2552
2570
2588
2606
2624
2642
2660
2678
2696
2714
2732
2750
2768
2786
2804
2822
2840
2858
2876
2894
2912
2930
2948
2966
2984
3002
3020
3038
3056
3074
3092
3110
3128
3146
3164
3182
1760 to 2450
OF
oc
960
966
971
977
982
988
993
999
1004
1010
1016
1021
1027
1032
1038
1043
1049
1054
1060
1066
1071
1077
1082
1088
1093
1099
1104
1110
1116
1121
1127
1132
1138
1143
1149
1154
1160
1166
1171
1177
1182
1188
1193
1199
1204
1210
1216
1221
1227
1232
1238
1243
1249
1254
1260
1266
1271
1277
1282
1288
1293
1299
1304
1310
1316
1321
1327
1332
1338
1343
1760
1770
1780
1790
1800
1810
1820
1830
1840
1850
1860
1870
1880
1890
1900
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
2010
2020
2030
2040
2050
2060
2070
2080
2090
2100
2110
2120
2130
2140
2150
2160
2170
2180
2190
2200
2210
2220
2230
2240
2250
2260
2270
2280
2290
2300
2310
2320
2330
2340
2350
2360
2370
2380
2390
2400
2410
2420
2430
2440
2450
3200
3218
3236
3254
3272
3290
3308
3326
3344
3362
3380
3398
3416
3434
3452
3470
3488
3506
3524
3542
3560
3578
3596
3614
3632
3650
3668
3686
3704
3722
3740
3758
3776
3794
3812
3830
3848
3866
3884
3902
3920
3938
3956
3974
3992
4010
4028
4046
4064
4082
4100
4118
4136
4154
4172
4190
4208
4226
4244
4262
4280
4298
4316
4334
4352
4370
4388
4406
4424
4442
2460 to 3000
OF
oc
1349
1354
1360
1366
1371
1377
1382
1388
1393
1399
1404
1410
1416
1421
1427
1432
1438
1443
1449
1454
1460
1466
1471
1477
1482
1488
1493
1499
1504
1510
1516
1521
1527
1532
1538
1543
1549
1554
1560
1566
1571
1577
1582
1588
1593
1599
1604
1610
1616
1621
1627
1632
1638
1643
1649
2460
2470
2480
2490
2500
2510
2520
2530
2540
2550
2560
2570
2580
2590
2600
2610
2620
2630
2640
2650
2660
2670
2680
2690
2700
2710
2720
2730
2740
2750
2760
2770
2780
2790
2800
2810
2820
2830
2840
2850
2860
2870
2880
2890
2900
2910
2920
2930
2940
2950
2960
2970
2980
2990
3000
4460
4478
4496
4514
4532
4550
4568
4586
4604
4622
4640
4658
4676
4694
4712
4730
4748
4766
4784
4802
4820
4838
4856
4874
4892
4910
4928
4946
4964
4982
5000
5018
5036
5054
5072
5090
5108
5126
5144
5162
5180
5198
5216
5234
5252
5270
5288
5306
5324
5342
5360
5378
5396
5414
5432
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
002 00
GEK 99441
31 May 2002
Page16
TABLE 4.
Conversion Table- Fractions to Decimals
Fraction
Decimal
Fraction
Decimal
Fraction
Decimal
1/64
0.0156
23/64
0.3594
45/64
0.7031
1/32
0.0312
3/8
0.3750
23/32
0.7188
3/64
0.0469
25/64
0.3906
47/64
0.7344
1/16
0.0625
13/32
0.4063
3/4
0.7500
5/64
0.0781
27/64
0.4219
49/64
0.7656
3/32
0.0938
7/16
0.4375
25/32
0.7813
7/64
0.1094
29/64
0.4531
51164
0.7969
1/8
0.1250
15/32
0.4688
13/16
0.8125
9/64
0.1406
31/64
0.4844
53/64
0.8281
5/32
0.1563
1/2
0.5000
27/32
0.8438
11/64
0.1719
33/64
0.5156
55/64
0.8594
3/16
0.1875
17/32
0.5313
7/8
0.8750
13/64
0.2031
35/64
0.5469
57/64
0.8906
7/32
0.2188
9/16
0.5625
29/32
0.9063
15/64
0.2344
37/64
0.5781
59/64
0.9219
1/4
0.2500
19/32
0.5938
15/16
0.9375
17/64
0.2656
39/64
0.6094
61/64
0.9531
9/32
0.2813
5/8
0.6250
31/32
0.9688
19/64
0.2969
41/64
0.6406
63/64
0.9844
5/16
0.3125
21/32
0.6563
1
1.0000
21/64
0.3281
43/64
0.6719
11/32
0.3438
11/16
0.6875
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
003 00
GEK 99441
Page 1 of 24
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
DESCRIPTION AND SPECIFICATIONS
Effectivity:
L32119G01 /-G03/
-G04/-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Consumable Materials ................................................................ .
Gas Turbine Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Turbine Components Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Pressure Turbine Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Turbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Turbine Systems Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication System............................................................ . . . . .
Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Geometry (VG) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction ........................................................................ .
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Gas Turbine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Turbine Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Equipment .................................................................. .
Page No.
2
6
16
7
6
6
11
16
18
18
19
22
22
22
22
23
23
23
1. INTRODUCTION. This work package provides general information for the LM500 gas turbine. Included in this work
package is a description of the gas turbine and its related systems, and the principles of operation.
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
None
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
4.
Page2
GAS TURBINE CHARACTERISTICS.
a.
The LM500 is a dual-rotor gas turbine with a single-rotor gas generator and an annular combustor. The gas generator (core engine) high-pressure turbine has two air-cooled axial-flow stages. The power turbine has four axial-tlow stages.
The power turbine drives an output shaft that passes concentrically forward inside the core engine rotor. The power turbine
output shaft rotates counterclockwise as viewed from the output shaft flange at the front of the gas turbine (forward looking
aft). The gas turbine-mounted accessory drive gearbox assembly is supported by the front frame. and incorporates pads for the
mounting of controls and accessories. The basic gas turbine (see figure I) consists of the following:
•
•
•
•
•
•
Front frame
Accessory drive gearbox assembly
Compressor section
Combustion section
High-pressure turbine section
Power turbine section.
b.
The LM500 gas turbine is designed to separate into major sections and structural units. Sectionalized construction is specifically oriented to provide maximum flexibility for maintenance tasks. This capability provides for sectionalized
repair or sectionalized replacement.
c.
The LM500 gas turbine is constructed with a high degree of accessibility. Detail features are specifically aimed
at individual component replacements. They are as follows:
•
Stator casing is split on horizontal line for easy access
•
All compressor blades, vane sectors. and vanes are individually replaceable
•
Fuel tubes and injectors are individually replaceable
•
High-pressure turbine (HPT) nozzle segments are individually replaceable
•
A limited number of HPT blades are replaceable without rotor balancing. or the HPT may be replaced as a
matched. prebalanced assembly
•
Power turbine rotor blades are individually replaceable
•
Power turbine is replaceable as an assembly
•
Compressor water-wash capability is provided
•
Mounted accessories and variable geometry system are provided.
d. The gas turbine has incorporated a number of ports, specifically located to provide access to the gas turbine's
interior to facilitate borescope inspection. Using the borescope procedure. inspection of the gas turbine's gas path can be
accomplished with the gas turbine installed.
e.
Design characteristics for the marine gas turbine are listed in table I.
f.
Design characteristics for the industrial gas turbine are listed in table 2.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
003 00
GEK 99441
Page3
31 May 2002
TURBINE
STATOR
ASSEMBLY
TURBINE
TRANSITION
ASSEMBLY
\
EXHAUST
FRAME
ASSEMBlY
EXHAUST
CENTERBOOY
LCIH-PRESSURE
TURBINE
STATOR
ASSEMBLY
ACCESSORY
DRIVE
GEARBOX
ASSEMBLY
1201 046-00-A2A
Figure I.
LM500 Gas Turbine Major Components
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 4
TABLE 1.
DESIGN CHARACTERISTICS (MARINE ONLY)
General
Type of Engine ....................................... .
Type of Compressor ................................... .
Number of Compressor Stages .......................... .
Variable Compressor Stators ............................ .
Type of Combustion Chamber ........................... .
High-Pressure Turbine Stages ........................... .
Gas Generator Rotor Speed ............................. .
Power Turbine Speed .................................. .
Power Turbine Stages ................................. .
Direction of Rotation .................................. .
Basic Gas Turbine Length .............................. .
Gas Turbine Weight (dry) .............................. .
Gas Turbine Length with Inlet and Exhaust Duct ............ .
Residual Fluids ...................................... .
Center of Gravity ..................................... .
Ambient Temperature ................................. .
Gas Turbine
Axial Flow
14
Inlet guide vanes, stator vane stages I through 5
Single, annular, through-flow
2
0-17.000 rpm (Normal)/17,600 (Max)
0-7.000 rpm (Normal)/7,700 rpm (Max)
4
Clockwise (aft looking forward)
86.14 inches (2.2 meters)
1.300 pounds (590 kg)
130.3 inches (3.3 meters)
Negligible
At Station 184.12
-65°F to 125oF (-54 oc to 52°C)
Fuel System
Fuel Specification
Manifold Inlet Pressure Required ........................
Manifold Inlet Temperature .............................
Flow Range: Standard Sea Level Conditions
Fuel LHV 18,400 Btu/lb
Idle .............................................
Maximum Power ...................................
Flow .............................................
Specific Gravity (Nominal)
.
.
.
.
.
NATO-F-75 (Liquid fuel: MIL-F-1688A)
GE Spec: MIL-TD-0000-2
270 psig (1862 kPa)
-65°F to 150°F (-54° to 66°C)
400 lb/hr ( 182 kg/hr)
2,800 lb/hr (I ,270 kg/hr)
290-3,400 lb/hr ( 132-1 ,543 kg/hr)
0.835 at 59°F (l5°C)
Ignition System
Ignition Exciter Input:
115 Vac
Voltage ........................................... .
Amperage ........................................ .
1.3 Amps
Frequency ........................................ . 50/60Hz
150VA
Power ............................................ .
Rating ............................................ . Intermittent (60 seconds between starts)
Duty Cycle (Max) .................................. . 2 minutes ON. 3 minutes OFF
2 minutes ON. 23 minutes OFF
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 5
TABLE 1.
DESIGN CHARACTERISTICS (MARINE ONLY) (Cant)
Gas Turbine Luhe and Hydraulic System
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-L-23699
Startup Oil Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 40°F (4.4°C) minimum
Luhe Pressure to Gas Turbine (Minimum) . . . . . . . . . . . . . . . . . . 30 psig (207 kPa) above sump pressure
Hydraulic Oil Pressure to VG Control . . . . . . . . . . . . . . . . . . . . . . 30-100 psig (207-690 kPa)
Luhe Temperature (to hearings)...........................
140°-l70°F (60°-7rC) (248oF (120oC) max)
Luhe Scavenge Temperature (B-sump) . . . . . . . . . . . . . . . . . . . . .
176°-3]0°F (80°-I55°C)
Luhe Pressure Normal Operation (to hearings) . . . . . . . . . . . . . . . 30-70 psig (207-483 kPa) above B-sump scavenge
pressure
Luhe Flow .......................................... . 9.9 gpm max (37.5 lpm)
Hydraulic Oil Flow ................................... . 9.0 gpm max (34.1 lpm)
10 microns
Filter Efficiency- Luhe and Hydraulic System .............. .
TABLE 2.
DESIGN CHARACTERISTICS (INDUSTRIAL ONLY)
General
Type of Engine ....................................... .
Type of Compressor ................................... .
Number of Compressor Stages .......................... .
Variable Compressor Stators ............................ .
Type of Combustion Chamber ........................... .
High-Pressure Turbine Stages ........................... .
Gas Generator Rotor Speed ............................. .
Power Turbine Speed .................................. .
Power Turbine Stages ................................. .
Direction of Rotation .................................. .
Basic Gas Turbine Length .............................. .
Gas Turbine Weight (dry) .............................. .
Residual Fluids ...................................... .
Center of Gravity ..................................... .
Fuel System
Fuel Specification .................................... .
Manifold Inlet Pressure Required ........................ .
Manifold Inlet Temperature ............................. .
Flow Range: Standard Sea Level Conditions
Fuel LHV 19,000 Btu/lh
Idle ............................................. .
Maximum Power ................................... .
Specitic Gravity (Nominal) ............................. .
Gas Turbine
Axial Flow
14
Inlet guide vanes, stator vane stages I through 5
Single, annular, through-flow
2
0-17,150 rpm (Normal)/17,360 (Max)
0-7.000 rpm (Normal)/7.050 rpm (Max)
4
Clockwise (aft looking forward)
130.2 inches (3.3 meters)
1,066 pounds (484 kg)
Negligible
At Station 186.34: 16 inches (406 mm) forward of
rear main mount
MID-S-00000-1 (natural gas fuel)
270 psig (I ,862 kPa)
-65° to 150°F (-54 o to 66°C)
4201b/hr(l91 kg/hr)
2.630 lb/hr ( 1.190 kg/hr)
0.568 at I 00°F (38°C)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 994.41
003 00
31 May 2002
Page 6
TABLE 2.
DESIGN CHARACTERISTICS (INDUSTRIAL ONLY) (Cant)
Ignition System
Ignition Exciter Input:
115 Vac
Voltage ........................................... .
1.3 Amps
Amperage ........................................ .
Frequency ........................................ . 60Hz
150VA
Power ............................................ .
Rating ........................................... . Intermittent (60 seconds between starts)
Duty Cycle (Max) .................................. . 2 minutes ON, 3 minutes OFF
2 minutes ON. 23 minutes OFF
Gas Turbine Lube and Hydraulic System
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-L-23699 or MIL-L-7807
Startup Oil Temperature:
MIL-L-23699 ................................... . +40°F (4.4oC) minimum
MIL-L-7807 .................................... . 0°F (-l8°C) minimum
Lube Pressure to Gas Turbine (Minimum) ................. . 30 psig (207 kPa) above sump pressure
Hydraulic Oil Pressure to VG Control ..................... . 30-1 00 psig (207 -690 kPa)
140°-l70°F (60°-77°C)
Lube Temperature (to bearings) .......................... .
I 00° -150°F (38° -66°C} above inlet temperature
Lube Scavenge Temperature (B-sump) .................... .
Lube Pressure Normal Operation (to bearings) .............. . 30-60 psig (207-415 kPa) above B-sump scavenge
pressure
Lube Flow .......................................... . 9.9 gpm max (37.5 lpm)
Hydraulic Oil Flow ................................... . 9.0 gpm max (34.1 !pm)
10 microns
Filter Efficiency - Lube and Hydraulic System .............. .
5.
GAS 1lJRBINE COMPONENTS DESCRIPTION.
a.
Front Frame. The front frame (see figure 2) is used to channel the air into the compressor rotor. Mating with the
inlet duct and housing, the front frame supports the A-sump No. I and No. 2 bearings, power turbine balance piston seal, and
stator casings. A reinforcing cone is bolted to the front frame to transfer mounting loads to the front frame struts. The compressor rotor is supported on its forward shaft by the No. 3 thrust hearing. also housed in the front frame. The accessory drive
gearbox assembly is also supported by the front frame by designated mounting pads cast into the frame. The front frame also
houses the nozzles for waterwashing the compressor rotor.
b.
Compressor Section.
(I)
Compressor Stator Casings. The steel compressor stator casings (see ligure 3) are split on a horizontal
plane for access to the compressor rotor. The casings contain three integral air manifolds: two at stage 7 for sump pressurization and one at stage I 0 for customer bleed air. The inlet guide vanes. as well as stator vanes. stages I through 5, are forged
steel alloy variable vanes. The inlet guide vanes and vanes in stages I and 2 are shrouded at the ID. The shrouds are split on a
horizontal plane to match the casings splitline. An extension of this half-ring acts as the interstage labyrinth seal seat on stages
I and 2. The sealing surface is pre-grooved to improve its capability to withstand seal rubs. Vanes in stages I through 5 are
individually replaceable. Vanes in stages 6 through 13 and the guide vanes are nickel base alloy. All are replaceable as sectors. Stages 6 through 13 sectors are inserted into the casing by means of circumferential grooves.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
003 00
GEK 99441
Page7
31 May 2002
o-RING SEAL RING
I'OWER TAKEOFF DRIVE
ASSEMBLY
/\1/ -{j --- --- --
.---I
I
I
I
I
I
RADIAL
DRIVE SHAFT
SHAFT
G-RING
--....,RETAINING RING
1201047-00-02
Figure 2.
Front Frame and Accessory Drive System
(2) Compressor Rotor. The 14-stage axial-flow compressor rotor assembly produces a pressure ratio of
approximately 14 to I. The compressor rotor (see figure 4) is a rigid drum, consisting of nickel alloy stage I disk, titanium
alloy stage 2 disk and front spool, and a nickel alloy stage 9 disk and rear spooL These are supported by tight tolerance bolts
on steel alloy forward and nickel alloy rear shafts, resulting in a rugged drum containing only two flange joints. The first two
stages have axially-oriented blade retention slots. The compressor spools and stage 9 disk contain circumferential grooves for
blade retention. These features allow blades to be removed easily. Stage I blades are made of steel alloy. Stages 2 through 9
blades are made of titanium alloy. Stages I 0 through 14 blades are made of nickel alloy. A stepped seal is mounted on the rear
shaft which mates with the static seal in the combustion section.
c.
Combustion Section.
(I) The combustion section (see figure 5) has a ring-type, or annular configuration combustion liner. The system provides high reliability for long turbine life and low smoke emission. The combustion chamber frame and the inner casing support the B-sump and the No. 4 and No. 5 roller bearings. The outer casing of the frame has pads for 18 removable fuel
injectors. P3 and T3 taps. igniters, and borescope inspection ports. The annular combustion liner is fabricated from shells
machined of Hastelloy X. The dome. which joins the inner and outer shells to form the liner assembly. has 18 fuel/air swirlers.
The compressor discharge static seal is made of Hastelloy X. The static seal is centered and bolted to the same flange that supports the forward end of the B-sump.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
003 00
GEK 99441
31 May 2002
PageS
CCiofPRESSOR
STATOR
CASINGS
1201048-00-A2A
Figure 3_
Compressor Stator Casings
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page_
003 00
GEK 99441
Page9
31 May 2002
REAR SHAFT
NO. 3
BEARING
HOOSING
OIL
TUBE
1201 049-00-A2A
Figure 4_
Compressor Rotor Assembly
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page_
003 00
GEK 99441
Page 10
31 May 2002
REAR MAIN MOUNT
IGNITER PORT (2)
OUTLET GUIDE VANES
AIR SEAL
C(MSUSTION
CHAMBER
FRAME
B·SUMP LUBE SUPPLY
AND SCAVENGE
FUEL INJECTOR PORT (18)
1201050-00-02
Figure 5.
Combustion Section
(2) Air leaving the compressor is diffused to approximately 60% of compressor discharge velocity in the prediffuser. and divides into three approximately equal streams at the dome entrance. Inner and outer cowls, supported from the
dome. capture compressor discharge air for metering air flow to the dome. Most of this air flow passes through the swirlers
and into the reaction zone where it serves as primary combustion air. The remainder of the air flow is used for cooling the
dome. Air passing into the inner and outer passages formed between the combustion liner shells and the combustion chamber
serves as primary air (to complete combustion). as dilution air (to reduce turbine inlet temperature). and as cooling air for combustion liner shell and other gas turbine hot parts. Primary air and dilution air is injected through the shells in radial and axial
holes, which meter the required amount of air to achieve the required depth of penetration. Shell cooling air is metered
through rows of small circular holes and is injected along the inner surface of the shells through annular slots along the combustor.
(3)
(Marine Only). Liquid fuel is metered. distributed. and introduced into the combustion chamber through
18 fuel injector hose assemblies which project into the swirlers of the combustion liner. The fuel manifold consists of 18 fuel
injectors permanently connected to the fuel tubes, connecting the manifold to the fuel distributor block assembly. The hot
combustion products exiting the primary zone are reduced to the required turbine inlet temperature by two rows of air jets in
both the outer and inner shells.
(4) (Industrial Only). Natural gas is distributed and introduced into the combustion chamber through 18 fuel
injectors which project into the swirlers of the combustion liner. The fuel manifold assembly consists of an annular tube of
right and left sections. Natural gas is fed to the fuel injectors through 18 fuel feed tubes connecting the manifold assembly to
the fuel injectors. The hot combustion products exiting the primary zone are reduced to the required turbine inlet temperature
by two rows of air jets in both the outer and the inner shells.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 11
(5) The swirler is a fuel/air mixing device in which fuel atomization and aeration is accomplished by highenergy air. This mixture is introduced into the combustor reaction zone in a wide cone angle. thus avoiding over-rich (high
fuel/air ratio) combustion and producing low smoke emissions. Ignition is accomplished by two igniter plugs. At ignition.
fuel is injected into the swirlers and the igniters are activated. After ignition. the igniters are deactivated by a control system
switch.
d.
High-Pressure Turbine Section.
(I)
The high-pressure turbine section (see figure I) consists of the turbine stator assembly. stage I nozzle
assembly. and turbine rotor assembly.
(2) The high-pressure turbine stator assembly (see figure 6) is located between the aft flange of the combustion
chamber frame and the forward flange of the turbine transition assembly.
(a) The stage I shroud segments. stage 2 turbine nozzle assembly, stage 2 turbine shroud segments and
support. stages I and 2 shroud retainers, and air baffle are all assembled inside a cylindrical air-cooled inner casing which is
bolted through a flange to the outer casing.
(b) There are 20 individually replaceable stage I shroud segments supported by ten shroud retainers and
a cylindrical groove in the inner casing. The 27 stage 2 nozzle segments also tit in similar inner casing grooves. The stage 2
shrouds cut in ten segments. are assembled in the stage 2 shroud support. The interstage seal consists of nine segments containing open-faced honeycomb. These segments are pinned to the inner radius of the stage 2 nozzle segments.
(c) The stage 2 turbine nozzle assembly. the outer and inner casings, and the air baffle have borescope
ports for inspection purposes.
(3)
The high-pressure stage I turbine nozzle assembly (see figure 7) is located at the aft end inside the combustion chamber frame and forward of the turbine rotor assembly.
(a)
The nozzle assembly consists of a nozzle inner support, nozzle segments. combustor outer seal, and
an air nozzle guide.
(b) The 24 nozzle segments are cast with two vanes on each segment. The segments are installed on the
circular outer flange of the nozzle inner support. The nozzle inner support locates the segments and prevents leakage. The
nozzle vanes are cooled by compressor discharge air by means of film cooling for the leading edge portions, and convection
and film cooling for the trailing edge portions. Inner and outer bands are cooled hy convection and film cooling.
(4) For all models except L321 19G06. the high-pressure turbine rotor assembly (see figure 8. sheet I) consists
of stage I and stage 2 turbine rotor disks bolted together by a torque coupling and contains internally-cooled stage I rotor
blades. Stage 2 rotor blades are not internally cooled. The rotor blades are held in position axially on each disk by a pair of
cooling plates, which are held by axial bolts through the disks. These plates also serve to seal against leakage of blade cooling
air. The cooling plates, which provide support for the outer torque coupling seal, seal the rotor cooling air. The plates have
baffles to reduce hot gas inflow to the rotor-to-stator cavities. The stage I rotor blades are cooled by air which flows through
holes in the dovetails and out the tip and trailing edge. The torque coupling has the rotating interstage seal teeth. A one-piece
conical shaft and air balance piston seal are bolted on the forward side of the stage I turbine disk with the same body-bound
bolts that hold the torque coupling to the rear of the stage I turbine disk. The shaft drives the compressor rotor by means of a
piloted spline coupling. The stage 2 turbine disk is coupled to the rear side of the torque coupling with the same type bodybound bolts.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
003 00
Page 12
31 May 2002
OUTER
CASING
""'
FOR
\
'
-..._-',
INNER
CASING
STAGE
SHROUD1
SEGMENT
\
STAGE 1
SHROUD
RETAINER
,I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
,_....._.__,//.,'STAGE 2
SHROUD
SUPPORT
STAGE 2 TURBINE
NOZZLE ASSEMBLY
Figure 6.
STAGE 2
SHROUD
RETAINER
c
OOOLMS-057800
High-Pressure Turbine Stator Assembly
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
003 00
GEK 99441
Page 13
31 May 2002
alMBUSTOR
OOTER SEAL
AIR NOZZLE GUIDE
NOZZLE SEGMENT
NOZZLE
INNER SUPPORT
1201051-00-A2A
Figure 7.
High-Pressure Stage I Turbine Nozzle Assembly
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 14
STAGE 2
ROTOR BLADES
, _ _ _ _ _ STAGE 2 tuRBINE
,ROTOR DISK
SHAFT
1201206-00-A2A
Figure 8.
High-Pressure Turbine Rotor Assembly (Sheet I of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
003 00
GEK 99441
31 May 2002
Page 15
STAGE 2
ROTOR BLADES
STAGE 1
ROTOR B
STAGE 2 TURBINE
ROTOR DISK
OUTER TORQUE COUPLING
AIR BALANCE
PISTON
(ROTATING)
SPLINE
COUPLING
SHAFT
MODEL L32119G06 ONLY
1201905-00-A2A
Figure 8.
High-Pressure Turbine Rotor Assembly (Sheet 2 of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 16
(5) For model L32119G06, the stages I and 2 turbine rotors consist of two turbine disks. The forward flange
of the stage 2 disk is bolted by body-bound type bolts to the aft end of the stage I disk (see figure 8. sheet 2). The stage I rotor
blades are internally-cooled serpentine blades. The stage I blades are cooled by air which flows through the holes in the dovetails and out the tip and trailing edge. The stage 2 rotor blades are not internally cooled. Both stages I and 2 blades are
retained to the disks by fir-tree type dovetails. The blades are held in position axially on each disk by two cooling plates.
(a) The cooling plates are held in position onto the disks by retaining rings. The cooling plates serve to
seal against any leakage of blade cooling air, provide support for the outer torque coupling. and seal the rotor cooling air. Also.
the plates contain projections which act as baffles to reduce the hot gas in-flow into the rotor-to-stator cavities. The outer
torque coupling carries the rotating interstage seal teeth.
(b) A single conical rotor shaft and a balance piston seal are bolted on the forward side of the stage I
disk with the same body-bound bolts that attach the flange of the stage 2 disk to the aft side of the stage I disk. The rotor shaft
drives the compressor by means of a piloted spline coupling.
e.
Power Turbine Section.
(I)
The power turbine section consists of the turbine transition assembly. low-pressure turbine stator assembly,
power turbine rotor assembly. and the exhaust frame assembly.
(2) The turbine transition assembly (see figure 9) is the duct for the hot gases leaving the high pressure turbine
rotor. The transition assembly funnels the hot gases into the larger diameter power turbine rotor. Inside the transition casing is
the stage 3 nozzle, the liner forward seal, and the outer transition liner. The stage 3 nozzle consists of 11 nozzle segments and
is interlocked into the interturbine seal and liner. A thermocouple harness is mounted on the transition casing to detect power
turbine inlet temperature (T4.8) for control and indicating purposes.
(3)
The low-pressure turbine stator assembly (see figure I 0) consists of two stator casings which are split at the
6 and 12 o'clock positions. The stator casings can be removed without disassembling the gas turbine. The casings contain segmented turbine nozzle vanes (for stages 4. 5, and 6) and turbine shrouds (for stages 3 through 6 ). Codep coating is applied to
the first stage power turbine rotor blades and vanes. The shrouds have four segments per stage and open-faced honeycomb surfaces. The stator casings have two borescope ports for inspecting stages 4 and 5 nozzle segments and stages 3 and 5 power
turbine blades.
(4) The power turbine rotor assembly (sec figure 11) consists of stages 3 through 6 turbine disks and blades.
The four disks and the interstage seals are bolted together with close tolerance bolts. Blades are held in the disks by the blade
retainers and the blades can be replaced without disassembling the rotor. The shrouded blade tips have an interlock feature that
keeps them rigid. The rear shaft is bolted between stages 4 and 5 and is splined to the drive shaft. The No. 6 and No. 7 roller
bearings support the rear shaft. The drive shaft is supported at the forward end by the No. I bearing in the A-sump. The stages
3 and 5 turbine blades can be borescope inspected using the two borescope ports located on the turbine stator casings.
(5) The exhaust frame assembly (see figure 12) serves as the main structural support for the power turbine section. The outer and inner casings are joined together by six struts. The struts support the inner hub. which supports the
C-sump and the No. 6 and No. 7 bearings. The C-sump oil supply tube. C-sump aft scavenge, and C-sump forward scavenge
are routed through the struts. The frame also houses two power turbine speed sensors that are routed through the struts. The
aft scavenge tube is surrounded by the oil supply tube within the 6 o'clock strut to minimize any "coking" in the supply tube
due to high "soakback" temperature in this area following gas turbine shutdown.
f.
Accessory Drive Section.
(I)
The accessory drive section (see figure 13) consists of the power takeoff (PTO) drive assembly (I). radial
drive shaft (5). and accessory drive gearbox assembly (6).
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003 00
GEK 99441
Page 17
31 May 2002
T4.8 THERMOCOUPLE BOSS
NOZZLE
SEGMENT
INTERTURBINE
SEAL AND LINER
LINER
FORWARD
SEAL
OUTER
TRANSITION
LINER
n---- TRANSITION
CASING
c
OOOLMS-057900
Figure 9.
Turbine Transition Assembly
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
003 00
GEK 99441
31 May 2002
Page 18
STAGES 4. s. AND 6
NOZZLE SEGMENTS
STATOR
CASING
VIEW IN DIRECTION OF A
Figure 10.
1201052-00-02
Low-Pressure Turbine Stator Assembly
(2) The PTO assembly (I) is located in the compressor front frame (7) as part of the A-sump. The PTO assembly consists of a PTO bevel gear (3) and a nozzle tube assembly (2) for lubrication to the No_ 3 bearing. splines, and bevel gear.
(3)
The radial drive shaft (5) transmits power to the gearbox assembly (6) through the bevel gear (3)_
(4) The gearbox assembly (6) is supported by the front frame (7)_ An external spline on the lower end of the
radial drive shaft (5) engages with an internal spline in the gearshaft in the gearbox assembly thus engaging a train of spur
gears within the gearbox assembly. The spur gears provide the mechanical drives for the gas turbine and customer's accessories. The gearbox assembly (6) also provides a cranking pad, the mounting support. and drivepads for the variable geometry
control, gas generator speed sensors, gas turbine lube and scavenge pump. fuel pump (Marine Only). and starter.
6. GAS TIJRBINE SYSTEMS DESCRIPTION. The gas turbine systems include the pressurization air, and portions of
the electrical. fuel. lubrication, and variable geometry systems. The engine portions of these systems are described in this
section.
a.
Air System. Air enters the gas turbine through the front frame to the compressor rotor. where the air is compressed at a ratio of approximately 14 to I. About one-fourth of the compressor discharge air is used for combustion. The
remaining air is used for diluting combustion gases to ensure safe operating turbine inlet temperatures. hot section cooling.
seat pressurizing. high-pressure rotor thrust balance. and the power turbine balance piston. Seal and balance piston pressurization air is bled from the seventh stage of the compressor rotor_ Air to the balance piston and B-sump cavities is unregulated.
Seal pressurization air to the A- and C-sumps is controlled to 15 psig (I 03 kPa) by a pressure regulating valve mounted on the
outside of the compressor casing. Only the airflow to the A-sump passes through a water trap/separator to remove any waterwash solution or water in the compressor airstream and prevent corrosion within the sump_ The B- and C-sumps operate at
higher temperature to vaporize and expel any water in the pressurizing airstream.
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003 00
GEK 99441
Page 19
31 May 2002
VIEW AFT LOOKING
FORWARD
STAGE 3
TURBINE DISK AND
BLADES
STAGE 4
TURBINE
DISK AND
BLADES
STAGE 6
TURBINE DISK AND
.::.
BLADES
·:::::::.
DRIVE CONE
NO. 7 ROLLER
BEARING
NO. 6 ROLLER
BEARING
AIR/OIL SEPARATOR
LOCKNUT
1201 053-00-A2A
Figure I I.
b.
Power Turbine Rotor Assembly
Electrical System.
(I)
Ignition System.
(a) The ignition system on the LM500 gas turbine consists of an ignition exciter and two integral igniter
plug lead assemblies. The exciter is an intermittent duty, dual output. capacitor discharge unit requiring a 115 V, 60Hz electrical power input. Two separate and independent circuits arc contained in the exciter, each including a filter network. a stepup
transformer. a rectifier circuit. a storage capacitor. an ionization tube, and a bleed resistor.
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003 00
GEK 99441
31 May 2002
Page 20
EXHAUST
CENTERBODY
FORHARD
HEAT
SHIELD
NO. 6 BEARING
CARBON SEAL
C-SUMP
OIL SUPPLY
AND
C-SUMP AFT
SCAVENGE
1201 054-00-D2A
PORT
Figure 12.
Exhaust Frame Assembly
(b) The two igniter plugs are connected to the ignition exciter by two separate igniter leads. The plugs
are located in bosses in the combustion chamber frame at the 2 and 10 o'clock positions. They consist of a center and an outer
electrode. with a semiconductor surface coating at the tip between the two electrodes. The semiconductor material is used as a
shunt to aid in ionizing the air gap between the two electrodes so that the plugs will fire. An air shroud covers the end of the
plug immersed in the air stream. Cooling holes under the flange area of the plug admit outer combustor flowpath air which
discharges across the plug tip for cooling purposes.
(c)
The ignition system is not required for gas turbine operation after starting, and is secured to prolong
service life.
(2) Thermocouple Harness. Actual power turbine inlet temperature is sensed by a rigid, two-piece thermocouple harness consisting of a total of ten probes with alternating immersion depths located in the turbine transition assembly.
There are two separate circuits in the harness with each probe containing two chromel-alumel thermocouple junctions. The
junctions for each circuit are connected in parallel to provide a signal of average power turbine inlet temperature.
(3) Power Turbine Speed Sensors and Vibration Transducers. There are two power turbine speed sensors on
the LM500 gas turbine. Each sensor is an electromagnetic device consisting of a coil-wound permanent magnet. The sensor is
located over the rotating No. 7 hearing inner race locknut. The wrenching splines on this locknut intermittently bends the
magnetic field set up by the permanent magnet in the inner tip of the sensor and induces a pulsating voltage in the internal coil.
The frequency of this voltage signal is an indication of power turbine speed. Also, included on the gas turbine are mounting
pads for two accelerometer-type vibration transducers (Industrial Only) located at 3 o'clock position on the compressor front
frame and at 12 o'clock position on the exhaust frame. The vibration transducers are used to monitor radial movement as a
result of gas turbine vibration.
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003 00
GEK 99441
31 May 2002
Page 21
J
1. Power Takeoff (PTO)
Drive Assembly
2. Nozzle Tube Assembly
3. PTO Bevel Gear
4. ExternalSpline
5. Radial Drive Shaft
6. Accessory Drive Gearbox
Assembly
7. Compressor Front Frame
c
OOOLM5-058000
Figure 13.
Accessory Drive Section
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GEK 99441
003 00
31 May 2002
(4)
Page 22
Chip Detectors.
(a) Continuity-type magnetic chip detectors are used in the gas turbine lubrication system. During normal gas turbine operation, some accumulation of fuzz-like magnetic particles will be found on chip detectors when they are
removed and inspected. Other materials, such as non-metallic sludge, small silver or non-magnetic flakes, bronze powder or
machining chips of aluminum (the latter especially on new gas turbines). may accumulate on the tip.
(b) Periodically, chip detectors should be checked for continuity, from cent er post to body. Continuity is
an indication of contamination. A significant increase in amount of change in makeup of accumulated material should be further evaluated by spectrometric oil analysis (WP 015 00).
c.
Fuel System.
(I)
(Marine Only). The fuel system distributes liquid fuel to the combustor. The gas turbine mounted components include a fuel filter with impending bypass indicator, fuel pump. fuel injector hose assemblies. and fuel distributor block
assembly. The fuel injector system consists of each fuel injector permanently connected to the fuel tubes.
(2) (Industrial Only). The fuel system distributes natural gas to the combustor. The on-engine fuel system
components include a manifold assembly, fuel feed tubes. and fuel injectors. The customer-provided fuel control and supply
system are not part of the gas turbine. Natural gas enters the two-piece manifold assembly. The fuel feed tubes direct the natural gas from the manifold assembly to the 18 fuel injectors which are inserted into the fuel swirlers of the combustion liner.
Compressor discharge air flows radially inward through the primary swirler in the combustion liner. which causes the air to
rotate circumferentially and mix with the natural gas. Air entering radially inward through the secondary swirler is caused to
rotate in the opposite direction. As the two counter rotating mixtures join, the natural gas mixes completely with the air. This
process also promotes more complete mixing of the natural gas and air and. therefore, more complete burning of the mixture
resulting in less smoke emission and a more uniform temperature distribution within the combustor.
(3) Ignition is accomplished by two igniter plugs. At ignition, fuel is injected into the swirlers and the igniters
are activated. After ignition, the igniters are deactivated by a customer-provided switch.
d. Lubrication System. The lubrication system provides oil for lubricating and cooling the gas turbine main bearings, supplies hydraulic fluid for variable geometry actuation system and fuel metering valve actuator, and cools the air delivered to the power turbine balance piston. System pressure is provided by a positive displacement supply and scavenge pump.
On-engine components include the main lube and scavenge pump, A-sump scavenge pump (all models except L32119G06),
oil filter. oil supply resistance temperature detector (RTD), oil scavenge RTD. magnetic chip detectors, and related piping.
e.
Starting System. The starter is mounted on the aft face of the accessory drive gearbox assembly, on the right
side, aft looking forward. The starter drives the gas generator through the gearbox to a speed at which the gas turbine can sustain itself. In addition, the starter can be used for gas turbine waterwashing and other preventive maintenance. The starter is a
hydraulic. variable displacement-type motor with pressure compensating control. The starter is equipped with an over running
clutch to prevent the starter from being driven by the gas turbine when the hydraulic pressure and flow reach zero. The starter
weighs approximately 50 pounds (23 kg). The starter is capable of operation at 0-1 00% salt air atmosphere.
f.
Variable Geometry (VG) System. The variable geometry system positions the compressor rotor variable-controlled stator vanes (VSV). This system is supplied with an on-engine compressor variable geometry control. which is selfcontained and is mounted on the accessory drive gearbox assembly. The VG control positions the compressor variable stators
as a function of gas generator rotor speed and compressor inlet temperature. The output of the control is regulated hydraulic
oil pressure supplied to the head and to the rod ends of two VG actuators. These VG actuators position two actuator linkage
assembly shafts on both sides of the compressor stator casings, which act through mechanical linkage to rotate the inlet guide
vanes (IGV's) and VSV's in stages I through 5. A feedback position linkage. mounted to one VG actuator shaft on the gas turbine and to the feedback position lever on the VG control, nulls out the control output pressure when the vanes have reached
their correct position for that corrected gas turbine speed.
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003 00
GEK 99441
31 May 2002
7.
Page 23
PRINCIPLES OF OPERATION.
a.
Basic Gas Turbine Operation. The LM500 is a gas turbine consisting of a gas generator. or core engine. and an
aerodynamically coupled power turbine. The core engine is started and assisted to idle speed by an external power source
driven through an accessory drive gearbox assembly. and an electrical ignition system. Once the gas turbine reaches idle speed
it is self-sustaming. requiring only a supply of air and fuel. The compressor draws inlet air that is compressed and discharged
through a diffuser into a combustion chamber frame. There. fuel is injected and mixed with the airflow for combustion. The
high-temperature combustion gases pass through an impulse-reaction high-pressure turbine (HPT). The HPT is mechanically
coupled to the compressor rotor, which is directly connected to a 90-degree power takeoff (PTO) gearbox at the compressor
inlet. The PTO drives an accessory drive gearbox through a drive shaft extending radially outward from the gas turbine centerline. About two-thirds of the energy in the combustion gas is required to maintain the core gas turbine cycle. The remaining
energy in the gas tlow is utilized to drive a free low-pressure power turbine. The power turbine rotor is directly connected to
an output shaft at the front of the gas turbine by a shaft passing through the core engine. The LM500 gas turbine may therefore
be categorized as a cold-end drive gas turbine engine.
h.
Gas Turbine Control System Operation.
(I)
Variable Geometry Control System:
(a)
The variable geometry (VG) control system uses the following input parameters:
•
Gas generator speed. by means of a centrifugal flyweight assembly.
•
Compressor inlet temperature. by means of an integraL remotely
mounted sensor on the inlet.
•
Variable stator vane position by means of a mechanical feedback
input to the control from the VSV linkage.
(b) The variable geometry control positions the gas generator variable stator vanes, as a non-linear function of gas generator speed and inlet temperature. The output of the control is regulated hydraulic oil pressure which is supplied to two VG actuators at the 4 and I0 o'clock positions (forward looking aft) on the front frame.
(c) The VG control includes an integral hydraulic pump that has enough capacity to satisfy the demands
of the VG actuator system. and provide the steady-state internal cooling tlow to the VG actuators.
(2)
Speed (RPM) Sensing:
(a) The gas generator speed sensors are located and driven through the accessory drive gearbox assembly. and provide electrical signals that are proportional to gas generator high-pressure turbine rotor speed.
(h) The power turbine speed signals are generated by two (redundant) speed sensor assemblies. mounted
in the power turbine exhaust frame. These sensor assemblies provide electrical signals in direct proportion to power turbine
speed. The pickups generate a magnetic field. encompassing a multi tooth gear or locknut rotating in close proximity to the
transducer head. The resulting variations in magnetic tlux generate an ac signal voltage.
(3)
Temperature Sensing:
(a) A two-piece (right- and left-hand) thermocouple harness is mounted on the turbine transition assembly, with probes sensing the high-pressure turbine discharge power turbine inlet temperature (T4.8). The probes have redundant junctions and leads to provide separate circuits for gas turbine control and operator indication.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
003 00
31 May 2002
Page 24
(b)
temperature profile.
(4)
The respective right- and left-hand circuits must be connected in parallel to provide an average of the
Pressure Ratio Sensing:
(a) Taps are provided on the gas generator for compressor discharge static pressure (PS3) and high-pressure turbine discharge pressure.
(b)
A probe is available to sense HPT total pressure (PT4.8) for control or condition monitoring.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 1 of 18
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
INSTALLATION AND REMOVAL OF GAS TURBINE INTO/FROM SHIPPING CONTAINER
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G01 /-G03/-G04/
G05/G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................
Description of Shipping Container I 06C7556 .............................................
Handling Equipment for Gas Turbine ....................................................
Inspection and Minor Repair of Shipping Container I06C7556 Prior to Use .....................
Installation of Gas Turbine into Shipping Container I 06C7556 ................................
Introduction ........................................................................
Removal of Gas Turbine from Shipping Container I 06C7556 .................................
Storage and Maintenance of Gas Turbine While in Shipping Container I06C7556 ................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
2
2
7
13
15
11
5
I
1. INTRODUCTION. This work package provides a description of the gas turbine shipping container. a procedure for
maintaining the protective environment within the container during extended storage periods. instructions for gas turbine
removal and installation from/into shipping container. and inspection and minor repair of shipping container prior to use.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
IC7300GOI
Fixture. Lift
IC7301G02
Stand, Support and Maintenance
106C7556
Container, Shipping
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00400
GEK 99441
31 May 2002
3.
Page2
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
he substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Brush. Wire
Local Purchase
Desiccant. Type I,
(MIL-D- 3464)
Davidson Chemical Co.
Baltimore. MD
USA
Enamel. Paint
(MIL-E-529)
Local Purchase
Gasket Material.
Class II, Grade 60
(MIL-R-6855)
Local Purchase
Ink. Stencil
Local Purchase
Primer. Zinc Chromate, Type II
(MIL-P-23377 or MIL-P-8585)
Kop-Coat, Inc.
480 Frelinghuyser Ave.
Newark. NJ 07114
USA
DESCRIPTION OF SHIPPING CONTAINER 106C7556.
I CAUTION
•
•
\
When lifting shipping container with gas turbine
inside. the hoisting device must have a 2-1/2 ton
(2500 kg) capacity.
When lifting an empty shipping container or the gas
turbine alone. the hoisting device must have a minimum capacity of 1-1/2 ton (1500 kg).
a.
The I 06C7556 shipping container is designed specifically for the LM500 gas turbine. The physical dimensions
are approximately 61 inches (!55 cm) high by 52 inches ( 132 cm) wide by 125 inches (318 cm) long. Empty container weight
is 2000 pounds (907 kg). Weight with gas turbine and accessory drive gearbox assembly is 3300 pounds (1497 kg). Shipping
container has side compartment record storage. enclosed pressure/vacuum relief valves, and uses ordinary capscrews around
the cover flange. Figures I and 2 illustrate this container.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 3
CAUTION: RELEASE PRESSURE BEFORE OPENING CONTAINER
16
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Stud
Automatic Pressure Relief Valve
Capscrew
Automatic Vacuum Relief Valve
Valve Mount and Desiccant Access Cup
Pressurizing Valve
Nameplate
Viewing Ports
Capscrew (Typical)
Locknut (Typical}
Data Plate
Locknut
Service Cover
Drainplug
Record Storage Container
Humidity Indicator
Nameplate
3
SERVICE VALVES AND DESICCANT ACCESS
(DESICCANT COVER REMOVED)
c
OOOLM5-027001
Figure I.
Shipping Container I06C7556 Service Fittings
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
Page4
31 May 2002
8
3
SECTION A-A
1. Front Support Mounting Bolts
2. Container Front Crossmember
3. Engine Front Support Plate
4. Left and Right Engine Mount Links
5. Fork Pockets
6. Loose Parts Storage Rack
7. Desiccant Bag Container
8. Lifting Sling Attachment Points
9. Desiccant Service Cover
c
OOOLM5-027101
Figure 2.
b.
Gas Turbine in Shipping Container 106C7556
Gas Turbine Protection Capability.
(I) Environmental protection of the gas turbine from corrosive elements or particles in the atmosphere is provided by the shipping container for an indefinite period. if the seals remain intact and internal pressure is maintained.
(2) When transporting the gas turbine. the shipping container provides protection from static and dynamic
loads. Static loads are limited to stacking a maximum of two containers. Dynamic loads of 3 g's vertically and axially. and
1.5 g's transversely, will be absorbed without damage to the gas turbine. The low frequency (2.5 to 7.5 Hz) vibration loads that
may occur during transportation are also absorbed.
(3)
Handling provisions include four lifting sling attachment points (8, figure 2). fork pockets (5). and surface
skids.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
004 00
GEK 99441
Page 5
31 May 2002
5.
STORAGE AND MAINTENANCE OF GAS TIJRBINE WHILE IN SHIPPING CONTAINER 106C7556.
NOTE
As received, the gas turbine installed into the shipping container has been preserved. packed for shipment. and hermetically sealed with humidity control and humidity indicator.
The following instructions verify that a safe environment is
maintained during long-term storage in the shipping
container.
a.
The following terms are used to describe the environment:
•
Normal Environment:
Temperature
Relative humidity
•
25°F to 85°F (-4°C to 29°C)
25'K to 65o/c
Extreme Environments:
Temperature
Relative humidity
-45oF to 24oF (-43°C to 4oC)
107< to 24%
and
Temperature
Relative humidity
86°F to 120°F (30°C to 49°C)
66'K to I OOo/r
b.
Store containers in area protected from direct sunlight, and. if possible, within limits of normal environment.
c.
Do the following maintenance checks of container every 60 days or as noted:
(I) Using pressure gage at pressurizing valve (6, figure I), check container internal pressure and inspect
humidity indicator ( 16) as follows:
(2)
(a)
Pressure must be 1-3 psig (7-21 kPa).
(h)
Humidity indicator (16) must show a blue color (indicating low humidity).
If pressure is less than I psig (7 kPa) and the humidity indicator is blue, do the following:
(a)
Using an air chuck fitting, repressurize container to 2-4 psig ( 14-28 kPa) with dry. filtered dehy-
(b)
Recheck container at 30-day intervals following procedure in step (I).
drated air.
(c) If the container internal pressure is found low during several inspection periods or in any two consecutive inspection periods, repressurize container and inspect all ports and flanges for leaks using soap-water solution.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00400
31 May 2002
Page6
I WARNING I
Removing Shipping Container Cover
To prevent personal injury. do not loosen nuts and bolts that
secure cover until shipping container has been
depressurized.
(d) If leaks are found. release container pressure. Repair leaks or replace leaking seals. valves, and/or
gaskets as required. Replace desiccant as described in paragraph e.
(e) If pressure is less than I psig (7 kPa) and the humidity indicator has turned pink (indicating high
humidity), do the following:
I
Replace desiccant (para e).
2 Return gas turbine (in shipping container) to an overhaul facility for inspection of bearings for corrosion and represervation. Tag container for overhaul and expedite return.
d.
Desiccant Time Replacement.
(I)
(2)
e.
The frequency of desiccant replacement with favorable periodic inspection is as follows:
(a)
Five years for normal environments.
(b)
Five years for extremely cold or hot and dry (relative humidity of less than 407() environments.
(c)
Three years for extremely hot and humid (relative humidity of over 40%) environments.
Replace desiccant (para e).
Desiccant Replacement Method.
NOTE
Containers are equipped with a service cover ( 13. figure I)
for replacing desiccant without removing the container
cover.
(I)
Release container pressure as follows:
(a)
Depress pressurizing valve (6) on service cover (13 ).
(b)
Manually depress relief valve poppets in center of automatic pressure relief valve (2).
(c)
Remove drainplug (14).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
004 00
GEK 99441
Page7
31 May 2002
I WARNING I
Removing Shipping Container Cover
To prevent personal injury, do not loosen nuts and bolts that
secure cover until shipping container has been
depressurized.
(2)
capscrews (3).
Remove valve mount and desiccant access cup (5) by removing service cover (13), two studs (1 ), and two
(3) Remove and discard the existing desiccant hags from container. Place 16 new units of desiccant hags
MIL-D-3464, Type I.
6.
(4)
Inspect gasket on access cup (5). Replace any gasket that might cause the container to leak.
(5)
Replace access cup (5). Tighten two studs (I) and two capscrews (3) to 40-60 lh in. (4.5-6.8 N·m).
(6)
Using an air chuck fitting, pressurize the container to 2-4 psig ( 14-28 kPa) with dry, filtered dehydrated air.
HANDLING EQUIPMENT FOR GAS 11JRBINE.
I CAUTION I
Use of slings or fixtures other than those recommended by
GE Aircraft Engines may result in external or internal damage to the gas turbine during handling or maintenance.
a.
Lift Fixture 1C7300GO 1. This fixture ( 1, figure 3) is designed as a close-coupled lifting device for removing or
installing the gas turbine into shipping container 106C7556 or onto maintenance stand 1C7301G02. Use the following procedures to attach lift fixture I C7300GO I to the gas turbine:
(I)
Place lift fixture (I) on top of gas turbine, with rear yoke (9) over rear main mount and forward support
block ( 10) resting on flange above compressor front frame.
(2)
Secure rear yoke (9) with halllockpin (4) through top rear ground handling hole (3).
(3)
Secure right and left links (5) on chains to gas turbine forward handling mounts (6) as follows:
(a) Insert pins (7) from beneath bosses at 10 and 2 o'clock positions through bosses and links. Work
around water-wash manifold as necessary.
(h)
(4)
Secure pins with cotter clips (8).
Position hoist (2) in proper position for configuration of gas turbine being handled as follows:
(a) For hare gas turbine. position saddle pin in fourth hole hack in hole grouping under ENG C/G stencil
mark (view B). Secure saddle pin with clevis pin.
(h) For gas turbine with accessory drive gearbox assembly installed, position saddle pin under ENG
W/GB C/G stencil mark. Secure saddle pin with clevis pin.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
PageS
ENG
CIG
00000
0
VIEWS
SADDLE
VIEW FORWARD LOOKING AFT
10
1/2
SEE VIEH 8
CAPACITY
""'""11'"
"""-r---2000
__
'
\
', E ;wGB
'
' .... _....
1
VIEW IN DIRECTION OF
A
NG
I
/
5
6
1.
2.
3.
4.
5.
6.
1.
8.
9.
10.
Lift Fixture 1C7300
Hoist
Top Rear Ground Handling Hole
Ball Lockpin
Right and Left links
Right and left forward Handling Mounts
Pin
Cotter Clips
Rear Yoke
forward Support Block
Figure 3.
1201055·00·A2A
Lift Fixture IC7300GO I Attachments to Gas Turbine
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 9
I WARNING I
Using Hoisting Devices
•
•
•
•
•
•
•
Hoisting shall only be done by designated personnel.
Do not exceed load capacity rating marked on hoist.
Inspection and testing for cracks or defects in hoisting
system shall be performed on a regular basis.
Use only pins, links, and hooks recommended for
hoisting specific components.
Before hoisting, balance the load.
Do not stand under load while it is being moved from
one area to another on a hoist. Do not stand under
load to do maintenance work.
Hoisting devices made of nylon, polyester, polypropylene, or aluminum shall not be used in areas where
caustics are handled.
(5) Attach hoist hook or cable at top of saddle and lift gas turbine slightly. If gas turbine is not being lifted horizontally and evenly, lower the gas turbine and reposition saddle, as necessary.
b.
Support and Maintenance Stand 1C730 I G02.
(I)
This stand (see figure 4) is designed to support the gas turbine at safe structural loading points. Also, this
stand is intended to support the gas turbine during the installation and removal of the accessory drive gearbox assembly and
gas turbine-mounted accessories.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 10
2
4
1.
2.
3.
4.
5.
6.
7.
3
Work Stand
Rear Flange
Clevis (Two)
Clevis Pins (Two)
Front Support (Two)
Front Mount Support Plate
Front Frame
c
OOOLM5-058100
Figure 4.
Gas Turbine onto Support and Maintenance Stand IC730 I G02
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
(2)
Page 11
Install gas turbine onto stand as follows:
I WARNING I
Using Hoisting Devices
•
•
•
•
•
•
•
Hoisting shall only be done by designated personnel.
Do not exceed load capacity rating marked on hoist.
Inspection and testing for cracks or defects in hoisting
system shall be performed on a regular basis.
Use only pins, links, and hooks recommended for
hoisting specific components.
Before hoisting. balance the load.
Do not stand under load while it is being moved from
one area to another on a hoist. Do not stand under
load to do maintenance work.
Hoisting devices made of nylon, polyester. polypropylene. or aluminum shall not be used in areas where
caustics are handled.
I CAUTION I
The maintenance stand has casters for easy positioning, but
it is not designed as a transportation dolly and must not be
used as such.
NOTE
The maintenance stand supports the gas turbine under two
angled bosses, behind the air intake flange. at 4 and 8
o'clock positions.
(a)
Using lift fixture I C7300GO I. position gas turbine above stand I C730 I G02.
(b) Lower the forward end of gas turbine slightly and move it down and forward guiding front frame (7)
onto front supports (5) and rear ball mounts within devises (3 ).
(c)
7.
Insert clevis pins (4) through devises (3) and ball mounts.
REMOVAL OF GAS TIJRBINE FROM SHIPPING CONTAINER 106C7556.
a.
Release pressure on shipping container (sec figure I) as follows:
(I)
Depress pressurizing valve (6) on service cover ( 13), or remove core of pressurizing valve.
(2)
Manually depress relief valve poppets in center of automatic pressure relief valve (2).
(3)
Remove drainplug (14).
(4)
Reinstall drain plug (14) and core of pressurizing valve (6) (if removed) when airtlow stops.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 12
I WARNING I
Removing Shipping Container Cover
To prevent personal injury, do not loosen nuts and bolts that
secure cover until shipping container has been
depressurized.
b.
Remove all capscrews (9) and locknuts (I 0) from cover flange.
I WARNING I
Using Hoisting Devices
•
•
•
•
•
•
•
Hoisting shall only be done by designated personnel.
Do not exceed load capacity rating marked on hoist.
Inspection and testing for cracks or defects in hoisting
system shall be performed on a regular basis.
Use only pins. links. and hooks recommended for
hoisting specific components.
Before hoisting. balance the load.
Do not stand under load while it is being moved from
one area to another on a hoist. Do not stand under
load to do maintenance work.
Hoisting devices made of nylon. polyester, polypropylene. or aluminum shall not be used in areas where
caustics are handled.
I CAUTION I
Cover must be lifted straight up to avoid damage to gas turbine or cover, using standard four-leg sling.
c.
Attach lifting sling at lifting sling attachment points (8. figure 2).
d.
Remove cover and place it onto wooden blocks to protect the sealing flange.
e.
Remove four front support mounting bolts (I) securing engine front support plate (3) to container front
crossmember (2).
f.
container.
Using lift fixture 1C7300GO 1 and instructions in paragraph 6.a .. prepare gas turbine for removal from shipping
g.
Raise gas turbine slightly to relieve weight on left and right engine mount links (4, figure 2). Remove ball-lock
link pins through engine rear mounts.
h.
Using instructions in paragraph 6.b., install gas turbine onto support and maintenance stand I C7301 G02.
i.
Detach engine front support plate (3, figure 2) from front frame mounting study by removing 36 nuts that secure
plate to mount core.
j.
If container is not to be reused immediately. install front engine support plate (3) to container front
crossmember (2 ).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
k.
Page 13
Reinstall ball-lock link pins.
I.
Reinstall container cover. Secure cover with locknuts (I 0. figure I) and capscrews (9). Torque capscrews to
30-50 lb ft (40.7-67.8 N·m).
m. If container is to be stored outdoors, pressurize container to 3 psig (21 kPa) so that weathertight seal can be
checked at 60-day intervals (refer to paragraph 5).
8.
INSPECTION AND MINOR REPAIR OF SHIPPING CONTAINER 106C7556 PRIOR TO USE.
I CAUTION I
•
•
Reusable shipping containers for current gas turbines
must not be used for purposes other than storage and
shipment of the gas turbine.
Reusable shipping containers are high-cost items procured and used for storage and shipment of gas turbines. These containers are procured in limited
quantities. and strict inventory control is maintained
to ensure their availability for all serviceable gas turbines placed in the supply system. The use of shipping containers is mandatory for all gas turbines
subject to indefinite storage and shipment.
a.
Containers must be inspected in accordance with the following criteria, prior to repair or reuse for the protection
of serviceable gas turbines:
(I)
Inspect bolts. nuts, and container mating surfaces for cracks. burrs, elongation, misalignment. defective
threads. and other mechanical defects that would affect serviceability.
NOTE
Pay particular attention to gas turbine suspension system
bolts during this inspection.
(2) Inspect braces. lifting rings. eyes. or 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 the closure flanges for cracks. dents, misalignment. and other defects which would affect sealing of
the container. Check for flushness of the repaired area using suitable gages. Ordinarily. scattered pits not exceeding I /16 inch
( 1.6 mm) in depth will not require fill welding but will require loose rust removal.
(4) Inspect the closure flange gasket for permanent deformation. cuts. abrasions, or other surface defects
which would affect sealing of the container.
(5) Inspect the container top and bottom shell for dents, cracks. gouges. corrosion damage, holes, or ruptures
in the surface that would affect serviceability. Scratches or gouges not more than I 116 inch ( 1.6 mm) deep and dents not more
than 1/2 inch (12.7 mm) deep are acceptable without repair.
(6) Inspect skids for broken ends. splits, dry rot, and other defects that would affect serviceability. Splits not
exceeding 2 feet (61 cm) in length and 1/2 inch (12.7 mm) wide are acceptable without replacement.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
Page 14
31 May 2002
(7)
Inspect shock mounts for cracks. tears. bond separation. splits. and other defects that would affect
serviceability.
(8) Check the automatic pressure relief valve (2. figure I) for proper release pressure and for leakage. Relief
valve should release at 2.5-3.5 psig (17-24 kPa) and be bubble-tight at 2.5 psig (17 kPa).
(9) If the container has been reconditioned and was not used. pressurize and check for leaks. Containers
reconditioned for use must be checked for overall leakage simultaneously with final pressurization at the time the gas turbine
is preserved. The container leakage check, required on all containers after reconditioning or when used to protect a serviceable
gas turbine, may be accomplished by the following method:
(a) Install top half cover of container. Install and tighten flange bolts to 30-50 lb ft (40.7 -67.8 kPa). and
pressurize to 2-4 psig (14-28 kPa).
(b) Using a soap solution, check the container for leaks at mating flanges and areas where weld repairs
were accomplished. If no leaks are detected in these areas. allow the container to stay pressurized for 24 hours and recheck the
pressure with an accurate pressure gage. If noticeable pressure drop has not occurred, container can be considered free from
leaks.
( 10) To assure proper preservation maintenance of the gas turbine. all containers. that contain serviceable or
repairable gas turbines must have the following minimum markings:
•
•
•
•
•
•
•
Preservation type
Date of preservation
Name of preserving activity
Status of gas turbine (serviceable or repairable)
Gas turbine type
Gas turbine serial number
A minimum of six spaces for inspection records
labeled and titled as follows:
INSPECTION DATA
Activity
Date
( 11) A second area or part of a continuous area Jabeled "SHIPPING DATA" with a minimum of 5 square feet
(4645 cm 2 ) must be reserved for indicating shipping data, as necessary. A contrasting background must be provided for easy
reading. The following minimum information must be indicated:
SHIPPING DATA
•
•
•
•
•
•
•
•
Destination
Shipping activity
Number of units
Invoice number
Weight
Cube
Dimensions
Bill of lading.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00400
Page 15
31 May 2002
h.
Containers needing minor repairs or overhaul must he reconditioned only as necessary to restore the container to
a serviceable condition. The following procedures must be considered as applicable for minor repair:
(I)
Clean container interior to remove fuel, oil, rags, bolts, nuts, desiccant bags. and other debris.
(2) Using a wire brush. remove all loose rust from the container's internal and external surfaces including
mounting rails, desiccant baskets. attaching hardware, and closure flange gasket surfaces. Bolts, mounts. and other fasteners
which are badly corroded should be removed for replacement or chemical cleaning.
(3) Complete refinishing is unnecessary unless areas hare of paint exceed 25 percent of total surface area.
Wherever practicable. touchup of surfaces must be accomplished using the same general paint tones as originally applied.
Matching of colors is not necessary. When completely refinishing any painted surface, use enamel (MIL-E-529) in any available color or any spare or excess finishes which may be available. The use of special purpose colors such as red or yellow
must be avoided. Interior touchup must consist of a mist coat of zinc chromate primer (MIL-P-23377 or MIL-P-8585) followed by a wet coat of the same material.
(4) Replace any flange gaskets that have cuts, abrasions, or other surface defects that would affect sealing of
the container. Replacement gaskets may be fabricated locally using gasket material conforming to Specification MIL-R-6855,
Class II, Grade 60. All joints must be vulcanized to form a continuous gasket.
9.
INSTALLATION OF GAS TIJRBINE INTO SHIPPING CONTAINER 106C7556.
a.
Inspect shipping container (para 8).
CAUTION
Prior to installation of the gas turbine into shipping container, all slave test equipment must be removed and all
blank-off plates must be installed. All openings must be
plugged or capped as necessary. A final inspection should
be made to ensure all parts are installed or removed as
appropriate.
b.
Using lift fixture I C7300GO I and instructions in paragraph 6.a., prepare gas turbine for installation into shipping container.
c.
Attach engine front support plate (3, figure 2) to front frame mounting studs so that the support plate is indexed
to position front mount pads horizontally on either side of gas turbine vertical centerline.
d.
Secure support plate (3) with 36 nuts. Tighten nuts.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
004 00
GEK 99441
Page 16
31 May 2002
I WARNING I
Using Hoisting Devices
•
•
•
•
•
•
•
Hoisting shall only be done by designated personnel.
Do not exceed load capacity rating marked on hoist.
Inspection and testing for cracks or defects in hoisting
system shall be performed on a regular basis.
Use only pins. links. and hooks recommended for
hoisting specific components.
Before hoisting. balance the load.
Do not stand under load while it is being moved from
one area to another on a hoist. Do not stand under
load to do maintenance work.
Hoisting devices made of nylon, polyester. polypropylene, or aluminum shall not be used in areas where
caustics are handled.
e.
Lift gas turbine with lift fixture.
f.
Lower the gas turbine into container so that the support plate (3) rests on container front crossmember (2).
g.
Attach gas turbine rear mount-to-container yoke links to left and right rear mounts.
h.
Install four front support mounting bolts (I) to secure support plate (3) to container front crossmember (2).
1.
Relieve weight on lift fixture and remove fixture from gas turbine.
J.
Torque bolts (I) to 30-50 Jb ft (40.7-67.8 N·m).
k.
Replace desiccant bags in shipping container receptacle with fresh 16 unit desiccant bags (MIL-D-3464).
I.
Install container cover as follows:
(I)
Attach four standard four-leg lifting slings at lifting sling attachment points (8).
I WARNING I
Using Hoisting Devices
Observe warning preceding step e.
I CAUTION I
Cover must be installed straight down to avoid damage to
gas turbine or to cover.
(2)
Lift the cover and lower it onto gas turbine and onto bottom half of container cover.
(3)
Install capscrews (9, figure I) and locknuts (10). Torque locknuts to 30-50 lb ft (40.7-67.8 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
004 00
31 May 2002
Page 17/18
m. Using an air chuck fitting. pressurize container to 2-4 psig ( 14-28 kPa) with dry (dehydrated). filtered air. Verify
seal around cover flange and all container filL vent and drain ports for leakage with soap solution.
n.
Put gas turbine log book in container records compartment.
o.
Stencil gas turbine shipping container per the requirements of paragraph 8. steps a.( I 0) and a.( 11 ).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
005 00
GEK 99441
Page 1 of 10
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
OPERATION
OPERATING PROCEDURES AND LIMITS
Effectivity:
L32119G02
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Abnormal Running Conditions .........................................................
Compressor Stall .................................................................
Flameout ........................................................................
Fuel Flow .......................................................................
Hot Start ........................................................................
Oil Pressure .....................................................................
Overspeed .......................................................................
Overtemperature ..................................................................
Vibrations .......................................................................
Consumable Materials ................................................................
Emergency Shutdown ................................................................
Gas Turbine Inspection and Prestart Checks ...............................................
Introduction ........................................................................
Normal Operating Ranges and Limits ....................................................
Shutdown ..........................................................................
Starting and Shutdown Procedures ......................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8
10
9
9
8
9
9
9
9
2
8
6
2
8
7
1. INTRODUCTION. This work package provides operating instructions and limits for the LM500 Industrial gas turbine.
Also. this work package provides prestart checks, starting. and shutdown procedures.
a.
The instructions cover operation. They apply to routine and emergency conditions. When a fault exists. refer to
WP 006 00, TROUBLESHOOTING.
b. These instructions may not provide for every possible variation in equipment or situation to be met when operating the gas turbine. If additional information is needed, contact:
Manager. Customer Service and Product Support
Marine and Industrial Engine Projects Department
GE Aircraft Engines
Mail Drop S 155
Cincinnati. Ohio 45215
USA
2.
SUPPORT EQUIPMENT.
None
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
005 00
GEK 99441
31 May 2002
3.
Page2
CONSUMABLE MATERIALS.
None
4.
NORMAL OPERATING RANGES AND LIMITS.
a.
General. If a questionable condition exists. do not operate the gas turbine until a thorough investigation has been
made. Do not attempt a restart after a hot start, compressor stall. or other recognized problem without prior thorough investigation. Failure to do so can result in undue stress being imposed on gas turbine components. with immediate or subsequent
destructive failure of the gas turbine.
b.
Refer to table I for normal operating ranges and limits.
TABLE 1.
Item
a.
NORMAL OPERATING RANGES AND LIMITS
Value
Remarks
General.
(I) Physical speeds:
(a) Gas generator rotor (NI):
•
Idle
11 ,000-11 ,500 rpm
11,200 rpm
Typical speed range
Nominal speed
•
Operating Limit
17,150 rpm
Maximum rated
•
Shutdown Limit
17,300 rpm
Overspeed trip setpoint
•
Overspeed Limit
17.800 rpm
Gas generator
inspection required
(b) Power turbine shaft (N2):
•
Operating Limit
7,050 rpm
Maximum rated
•
Shutdown Limit
7.300 rpm
Alarm set point
•
Overspeed Limit
7,700 rpm
Overspeed trip setpoint. Any
observed/suspected rpm in
excess of this limit requires a
power turbine inspection.
(c) Locked rotor
Maximum 14 minutes at idle
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
Page 3
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cont)
Item
Value
Remarks
(2) Power turbine inlet total
temperature (T4.8 ):
•
Operating Limit
I.:nooF (745°C)
Max allowable during starts
•
Maximum Rated
1.380°F (750°C)
Alarm limit
•
Shutdown Limit
I .400°F (760°C)
Troubleshoot (WP 006 00).
•
Overtemperature Limit
1.555°F (850°C)
Power turbine inspection
required
-65° to 125°F
(-54 o to 52°C)
Do not operate gas turbine
outside this range.
(I) Fuel flow (Wf)
420 lh/hr (191 kg/hr)
nominal at idle.
2.360 lh/hr ( 1.194 kg/hr)
max at base load
Limits with fuel LHV of
19.000 BTU/lh nominal
(2) Specific gravity (nominal)
0.568 at I00°F (38°C)
(3) Fuel manifold pressure
270 psig ( 1.862 kPa)
minimum at rated load
(4) Leakage
No detectable vapor allowed.
(3) Ambient temperature
h.
c.
Fuel system (natural gas).
Lubrication.
( 1) Flow (to gas turbine)
0 to 9.9 gpm
(0 to 38lpm)
(2) Temperature at startup (minimum)
MIL-L-23699: 40°F (4°C)
MIL-L-7808: 0°F (-18°C)
(3) Luhe supply temperature
140°-l70°F
(60°-77°C)
(4) Scavenge temperature
176°-3l0°F
(80°-155°C)
Normal range
325°F (163°C)
for 15 minutes
Transients (alarm)
Proportional to gas generator
rotor (NI ) speed
Maximum (gas turbine cut-hack)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
Page 4
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cant)
Item
Value
Measured as differential pressure
between filter discharge (pump
connection) and the B-sump aft
scavenge pressure
(5) Gas turbine oil pressure at
200°F
oil temperature:
(a) Starting
Oil pressure should show a positive value during start and may
peak at I 00 psi (689 kPa) for a
maximum of 2.5 minutes when
operating in cold weather. Oil
pressure should start to decrease
after 2.5 minutes.
(b) Idle
34 to 54 psid (234-372 kPa)
(c) Above idle
60 to 87 psid (414-600 kPa)
(d) Transients
Oil pressure transients that
exceed the normal limits may
occur for a maximum of
6 minutes, if during the 6-minute
period. a steady decrease in pressure is occurring to return the
gas turbine toward normal
steady-state pressure.
(6) Oil consumption
Remarks
If limits are exceeded. shut down
gas turbine and troubleshoot
(WP 006 001.
0.07 gph (0.27 !ph)
(7) Sumps pressure:
(a) A-sump and accessory gearbox
Ambient to 4 psig (28 kPa)
(b) B-sump
55 psig (379 kPa) maximum
(c) C-sump
Ambient to 4 psig (28 kPa)
(8) Oil leakage (during operation):
(a) VG actuators
0.1 cc or 2 drops per minute
maximum
Isolate faulty actuator and
replace.
(b) A-sump drain
I cc or 20 drops/minute
maximum
Check for high sump pressure.
low pressurizing air regulation.
improper AGB scavenging, or
flooded sump.
(c) Accessory gearbox seal cavities
3 cc/hr or 60 drops/minute
minimum
(d) Gas turbine fittings or strut tubes
No observed leakage allowed
(9) Filter efficiency
I0 microns maximum
(lube and hydraulic oil)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
Page 5
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cont)
Item
(I 0) Change interval
d.
Value
Remarks
As indicated by SOAP
Refer to WP 015 00.
Vibration.
NOTE
Vibration limits are displayed at a one-per-revolution value of the indicated rotor.
For example. selecting "gas generator rotor vibration" for display will indicate
only gas generator (compressor) vibration on the front frame transducer; the
power turbine contribution to the total velocity seen by that transducer will be filtered out. Gas generator vibration will likewise be displayed from the turbine
frame transducer and power turbine vibrations will be filtered out.
(I) Vibration Monitoring:
Frequency
(cycles/second)
Pickup Location
Steady State
(mils-double
amplitude)
Transient
(mils-double
amplitude)
Direction and
Clock Position
Compressor casing
forward flange
25 to 130
130 to 310
3.5
2.5
4.5
3.5
I horizontal
Exhaust frame flange
25 to 130
130 to 310
5
3
6
I horizontal
4
(2) Corrective Action:
(a) Alarm:
Temporary operation is allowed between alarm and shutdown setpoints for transient conditions or
troubleshooting purposes. Throttle setting should be reduced, as necessary, to avoid steady-state
operation in an alarm condition.
(b) Shutdown:
e.
Operation above this vibration level is not allowed.
Starting.
Do not attempt restart until gas
generator rotor has stopped.
(I) Time from starter initiation to idle
45 seconds maximum
(2) Time to lightotT, from starter initiation
20 seconds maximum
(3) Starter seal drainage
5 cc/hr
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
5.
PageS
GAS WRBINE INSPECTION AND PRESTART CHECKS.
a.
General. If a questionable condition exists. do not operate the gas turbine until a thorough investigation has been
made. Do not attempt a restart after a hot start. compressor stall. or other recognized problem without prior thorough investigation. Failure to do so can result in undue stress being imposed on gas turbine components. with immediate or subsequent
destructive failure of the gas turbine.
b. Initial Operation Inspection. The initial operational period is that period of operation immediately following gas
turbine installation or replacement, or following major maintenance on the system. Do the following:
(I)
Verify that oil tank contains sufficient oil.
(2)
Using table 2, do a prestart system check.
(3)
Take oil sample (WP 015 00) for lab analysis prior to first motoring. unless oil has been changed as part of
gas turbine maintenance.
c.
Prestart Motoring (No Fuel).
Never allow fuel (natural gas) to enter the gas turbine during prestart motoring. If fuel flows into the gas
turbine. purge the fuel by motoring the gas turbine for a minimum of 15 seconds with no fuel flow.
(I)
(2)
Deactivate ignition circuit at unit circuit breaker.
(3)
Motor gas turbine to achieve max motoring speed on starter.
(4)
Check for:
(a)
Zero fuel flow (zero fuel manifold pressure).
(b)
Unusual rubbing or scraping noises.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
Page 7
TABLE 2.
PRESTART SYSTEM CHECKS
Item
Requirement
Maintenance requirements and discrepancies
Cleared
Fire and gas detection system
ON
Fuel valves
Closed
Ignition
OFF
Ventilation inlet air (secondary cooling air)
ON
Oil tank level
Full
Lube oil supply valves
Open
Lube oil temperature (in tank):
e
MIL-L-23699
40°F (4°C)
minimum
e
MIL-L-7808
ooF (-l8°C)
minimum
Water wash supply
Closed
Instrument gas valves
Open
(5)
(c)
Positive oil pressure indication within 30 seconds. Stop motoring if no oil pressure is indicated.
(d)
Lube leaks.
Record:
•
•
•
•
•
•
(6)
6.
Gas generator rotor speed (NI)
Power turbine output shaft speed (N2) (may be zero
at cranking speed)
Lube supply pressure
VG indication (should close)
Fuel tlow (should be 0)
Fuel manifold pressure (should be 0).
After 2 minutes (maximum). de-energize starter.
STARTING AND SHUTDOWN PROCEDURES.
a.
Before attempting to start gas turbine. observe the following precautions:
(I)
Before making an initial start. do gas turbine inspection and prestart checks (para 5).
(2)
Shut down gas turbine if any fuel or oil leaks are detected, or if there is no oil pressure indication within
30 seconds.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
005 00
31 May 2002
b.
7.
Page 8
Follow the operating limits and performance ratings given in table I.
SHUTDOWN.
a.
Stabilize gas turbine at idle (minimum speed) for 5 minutes.
b.
Close fuel valves.
c.
Monitor coastdown.
d.
Check for post shutdown fire by monitoring T4.8 for 3 minutes. If T4.8 does not decrease steadily after coastdown, close manual fuel valves and motor gas turbine until positive fuel shutotf is verified and fire is put out.
8.
EMERGENCY SHUTDOWN.
a.
An immediate shutdown from any power level may be made by de-energizing (closing) the fuel shutoff valves.
b.
Do not attempt a restart until the cause of the shutdown has been verified and corrected.
c.
Do a Prestart Motoring (para 5. c.) before attempting a restart.
d.
A tripout due to overspeed. fuel flow interruption, or other control system safety feature is considered an emergency shutdown, if the tripout shuts the gas turbine down.
9.
ABNORMAL RUNNING CONDITIONS.
a.
General.
(I)
If an abnormal gas turbine condition occurs, such as compressor stall, tlameout. or overtemperature, shut
down gas turbine. Record duration and degree of any abnormal condition. (Refer to table I for limits.)
(2) In most cases, continued operation of the gas turbine is permitted if the operator has been able to restore the
gas turbine parameters within limits from an alarm or abnormal condition. Troubleshooting must be conducted at the earliest
opportunity to find the cause of the problem, so as to preclude its reoccurrence during later operation. Causes of abnormal
operation may involve complex control logic and/or interactions between several systems. Ensure that adequate corrective
action has been taken prior to further operation.
b.
Hot Start.
(I)
If during a start T4.8 increases abnormally, shut the gas turbine down immediately and record highest
observed T4.8. (Refer to table I to determine if operating limits have been exceeded.)
(2)
If operating limits have been exceeded, troubleshoot (WP 006 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
005 00
GEK 99441
31 May 2002
c.
Page9
Overtemperature.
CAUTION
Do not operate gas turbine until cause of overtemperature
has been determined. An overtemperature inspection may
be necessary.
(I)
(2)
d.
e.
An overtemperature condition exists and requires an overtemperature inspection if:
(a)
During starting, T4.8 increases rapidly above I .700oF (927°C) immediately after lightoff.
(b)
After gas generator rotor reaches 8,900 rpm and T4.8 exceeds limits given in table I.
If an overtemperature condition exists, troubleshoot (WP 006 00).
Flameout.
(I)
Shut down gas turbine (para 7).
(2)
If operating limits have been exceeded. troubleshoot (WP 006 00).
Overspeed.
CAUTION
Do not operate gas turbine until cause of overspeed has been
determined and corrective action taken; otherwise, gas turbine damage may occur.
(I) If gas generator speed or power turbine output shaft speed exceeds the limits given in table I. or an overspeed trip occurs. shut down gas turbine.
(2)
f.
g.
h.
If operating limits have been exceeded, troubleshoot (WP 006 00).
Abnormal Oil Pressure.
(I)
Do not operate gas turbine if stabilized oil pressure is outside the limits given in table I.
(2)
If limits are exceeded, troubleshoot (WP 006 00).
Abnormal Fuel Flow.
(I)
Fuel flow is abnormal if it does not meet the operating limits given in table I.
(2)
If operating limits have been exceeded, troubleshoot (WP 006 00).
Abnormal Vibrations.
(I) High vibrations can be caused by rotor imbalance and by loose gas turbine mounts or other external connections. If operating limits have been exceeded, troubleshoot (WP 006 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
005 00
GEK 99441
Page 10
31 May 2002
(2) Occasionally, it may be noted that vibrations increase as much as 3 mils after a shutdown of I to 2 hours.
The most probable cause is a temporary thermal rotor bow due to uneven cooling of the power turbine or gas generator rotors.
If the shutdown is brief (less than I 0 minutes) or long (more than 6 hours). thermal rotor bow is controlled because the rotors
cool either very little or to a uniform temperature.
(3) A thermal rotor bow can be identified by noting that the increased vibration levels gradually decrease to
previous levels during approximately I 0 minutes of gas turbine operation. As long as vibrations are decreasing with time. gas
turbine operation may be continued even if some limits are temporarily exceeded.
i.
Compressor Stall.
(I) A compressor stall is caused by an aerodynamic disturbance of the smooth airflow pattern through the
compressor. A rapid increase of T4.8 and usually a speed hangup (although some stalls are accompanied by a rapid decrease
in speed) are indications of a stall. A change in gas turbine noise level may also be noted.
·
(2)
If a stall occurs. do the following:
(a)
Shut gas turbine down immediately.
I CAUTION I
Do not attempt a restart after a stall until cause has been
investigated.
(b)
If operating limits have been exceeded. troubleshoot (WP 006 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00510
GEK 99441
Page 1 of 12
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
OPERATION
OPERATING PROCEDURES AND LIMITS
Effectivity: L32119G01 /-G03/-G04/
-G05/-G06
MARINE GAS TURBINE
Alphabetical Index
Page No.
Subject
Abnormal Running Conditions .........................................................
Compressor Stall .................................................................
Flameout ........................................................................
Fuel Flow .......................................................................
General .........................................................................
Hot Start ........................................................................
Oil Pressure .....................................................................
Overspeed .......................................................................
Overtemperature ..................................................................
Vibrations .......................................................................
Consumable Materials ................................................................
Emergency Shutdown Procedure .......................................................
Gas Turbine Operation ...............................................................
Introduction ........................................................................
Motoring Procedure ..................................................................
Normal Operating Ranges and Limits ....................................................
Normal Operation ...................................................................
Normal Shutdown Procedure ..........................................................
Prestart Checks .....................................................................
Starting Procedure ...................................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
10
11
12
12
10
11
12
11
10
11
2
12
7
I
8
2
10
12
7
9
2
1. INTRODUCTION. This work package provides operating instructions and limits for the LM500 Marine gas turbine.
Also, this work package provides prestart checks. starting, and shutdown procedures.
a. The instructions cover operation. They apply to routine and emergency conditions. When a fault exists, refer to
WP 006 I 0. TROUBLESHOOTING.
b. These instructions may not provide for every possible variation in equipment or situation to be met when operating the gas turbine. If additional information is needed. contact:
Manager, Customer Service and Product Support
Marine and Industrial Engine Projects Department
GE Aircraft Engines
Mail DropS 156
Cincinnati. Ohio 45215
USA
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00510
31 May 2002
2.
Page2
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
None
4.
NORMAL OPERATING RANGES AND LIMITS.
a.
General. If a questionable condition exists. do not operate the gas turbine until a thorough investigation has been
made. Do not attempt a restart after a hot start. compressor stall, or other recognized problem without prior thorough investigation. Failure to do so can result in undue stress being imposed on gas turbine components. with immediate or subsequent
destructive failure of the gas turbine.
·
CAUTION
•
•
b.
Bypassing/disabling engine sensors or operating
engine with monitoring systems inoperative can result
in engine damage.
Overriding engine control permissives can result in
engine operational problems and engine damage.
Refer to table I for normal operating ranges and limits.
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS
Value
Item
a.
Remarks
General.
(I) Physical speeds:
NOTE
XN2R = Corrected gas generator speed
XN2 = Physical gas generator speed
(a) Gas generator rotor:
•
•
•
•
Idle (XN2)
(XN2R)
I I .000-1 I .500 rpm
11,200 rpm
Operating Limit
(XN2)
(XN2R)
17.600 rpm
17,200rpm
Typical speed range
Nominal speed
Maximum rated
Shutdown Limit
(XN2R)
17.700-17.900 rpm
Overspeed trip setpoint
Overspeed Limit (XN2)
18,150rpm
Gas generator inspection required
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GEK 99441
005 10
31 May 2002
Page 3
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cont)
Item
Value
Remarks
(b) Power turbine shaft (XNSD):
•
Operating Limit
7.050 rpm
Maximum rated
•
Alarm Limit
7,300 rpm
Alarm setpoint
•
Overspeed Limit
7,650-7.750 rpm
Overspeed trip setpoint
7.826 rpm
Any observed/suspected rpm in excess of
this limit requires a power turbine
inspection.
(c) Locked rotor
Maximum 14
minutes at idle
(2) Power turbine inlet total temperature
(T4.8):
•
•
•
•
Operating Limit
1395o to 1405°F
(757° to 763°C)
Max allowable during starts
Maximum Rated
1.549° to 1.560°F
(843° to 849°C)
Alarm limit
Shutdown Limit
1.580° to 1.591 oF
(860° to 866°C)
Troubleshoot (WP 006 I 0).
Overtemperature Limit
1.625°F (885°C)
Power turbine inspection required
-65° to 125°F
(-54° to 52oC)
Do not operate gas turbine outside this
range.
(I) Fuel flow (Wf)
290 lb/hr (132 kg/hr) to
3.400 lb/hr (I ,543 kg/hr)
maximum
Fuel type NATO-F-76, MIL-F-1688A
(2) Fuel manifold pressure
0 to 270 psi
(0 to 1.862 kPa)
(3) Leakage
5 cc/minute max from all
drains when running
(3) Ambient temperature
b.
c.
Fuel system (liquid fuel).
Lubrication.
(I) Flow (to gas turbine)
0 to 9.9 gpm
(0 to 38 !pm)
Proportional to gas generator rotor (XN2)
speed
(2) Temperature at startup (minimum)
MIL-L-23699:
40°F (4°C)
Preheat lube oil, if required, prior to start.
(3) Lube supply temperature
248°F ( 120°C)
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GEK 99441
005 10
31 May 2002
Page 4
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cant)
Item
(4) Scavenge temperature
Value
Remarks
176°-3]0°F
(80°-I55°C)
Normal range
329°-350°F
( 165°-I77°C)
for 15 minutes
Transients (alarm)
A hove
350°F ( I77°C)
Maximum (gas turbine cut-hack)
(5) Gas turbine oil pressure at
200°F (93°C) oil temperature:
Measured as differential pressure between
filter discharge (pump connection) and the
B-sump aft scavenge pressure
(a) Starting
Oil pressure should show a
positive value during start
and may peak at I 00 psi
(689 kPa) for a maximum of
2.5 minutes when operating
in cold weather. Oil pressure should start to decrease
after 2.5 minutes.
(h) Idle
35 to 55 psid (241-379 kPa)
(c) Ahove idle
40 to 70 psid (276-483 kPa)
(d) Transients
Oil pressure transients that
exceed the normal limits
may occur for a maximum
of 6 minutes. if during the
6-minutc period. a steady
decrease in pressure is
occurring to return the gas
turbine toward normal
steady-state pressure.
(6) Oil consumption
If limits are exceeded, shut down gas turbine and trouhleshoot (WP 006 10).
0.07 gph
(0.27 !ph)
(7) Sumps pressure:
(a) A-sump and accessory gearbox
Ambient to 4 psig (28 kPa)
(h) B-sump
55 psig (379 kPa) maximum
(c) C-sump
Ambient to 4 psig (28 kPa)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
005 10
31 May 2002
Page 5
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cant)
Item
Value
Remarks
(a) VG actuators
0.1 cc or 2 drops per minute
maximum
Isolate faulty actuator and replace.
(b) A-sump drain (may not be
applicable to some models)
I cc or 20 drops/minute
maxnnum
Check for high sump pressure, low pressurizing air regulation. improper AGB
scavenge. or flooded sump.
(c) Accessory gearbox seal cavities
3 cc/hr or 60 drops/minute
maximum
(d) Gas turbine fittings or strut
tubes
No observed leakage
allowed
(8) Oil leakage (during operation):
d.
(9) Filter efficiency
10 microns maximum
(lube and hydraulic oil)
(10) Change interval
As indicated by SOAP
Refer to WP 015 00.
Vibration.
NOTE
Vibration limits are displayed at a one-per-revolution value of the indicated rotor.
For example, selecting "gas generator rotor vibration" for display will indicate
only gas generator (compressor) vibration on the front frame transducer; the
power turbine contribution to the total velocity seen by that transducer will be filtered out. Gas generator vibration will likewise be displayed from the turbine
frame transducer and power turbine vibrations will be filtered out.
(I) Vibration Monitoring (all engines except as noted):
Transducer
Location
Vibration
Source (Symbol)
Alarm
Setpoint (Mils DAl
Shutdown
Setpoint (Mils DAl
Forward
GG
2.5
3.5
3.5
4.5
3
5
4
6
PT
Aft
GG
PT
(2) Vibration Monitoring - Danish Navy:
Transducer
Location
Vibration
Source (Symbol)
Alarm
Setpoint (Mils DA)
Shutdown
Setpoint (Mils DAl
Forward
GG
1.5
2.0
2.0
2.7
1.5
2.0
2.0
2.7
PT
Aft
GG
PT
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GEK 99441
005 10
31 May 2002
Page 6
TABLE 1.
NORMAL OPERATING RANGES AND LIMITS (Cant)
Item
Value
Remarks
(3) Vibration Monitoring- FoilCat/11 PG:
Transducer
Location
Vibration
Source (Symbol)
Alarm
Setpoint (Mils DA)
Forward
GG
2.5
3.5
PT
3.5
4.5
Aft
Shutdown
Setpoint (Mils DA)
GG
2.5
3.5
PT
3.5
4.5
(4) Corrective Action
(a) Alarm: Temporary operation is allowed between alarm and shutdown setpoints for transient conditions or
troubleshooting purposes. Throttle setting should be reduced, as necessary, to avoid steady-state
operation in an alarm condition.
(b) Shutdown: Operation above this vibration level is not allowed.
e.
Starting.
Do not attempt restart until gas generator
rotor has stopped.
(I) Time from starter initiation to idle
90 seconds maximum
(2) Time to lightoff, from starter
initiation
20 seconds maximum
(3) Starter seal drainage
5cc/hr
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00510
Page7
31 May 2002
5.
GAS TIJRBINE OPERATION.
a.
General. If a questionable condition exists. do not operate the gas turbine until a thorough investigation has been
made. Do not attempt a restart after a hot start. compressor stall. or other recognized problem without prior thorough investigation. Failure to do so can result in undue stress being imposed on gas turbine components. with immediate or subsequent
destructive failure of the gas turbine.
b.
Motoring. During motoring. the fuel supply system must provide pressurized fuel to the fuel pump to prevent
pump damage.
c.
Starting. Shut down the gas turbine if any fuel or oil leaks are detected. or if there is no oil pressure indication
within 30 seconds.
d.
Fire Extinguishing. If Halon fire extinguishing agent is used in the gas turbine compartment, the gas turbine
exterior must be cleaned per WP 017 00 prior to further operation.
6.
PRESTART CHECKS.
a.
General. The prestart system checks listed in table 2 should be performed prior to each gas turbine start. If
major maintenance has been performed, ensure that the affected systems and components have b_een restored for operation and
tested or aligned per the applicable work packages.
TABLE 2.
PRESTART SYSTEM CHECKS
Item
Requirement
Maintenance requirements and discrepancies
Cleared
Fire detection system
ON
Hydraulic starter supply system
Ready
Fuel supply valves
Open
Fuel supply pump
ON
Gas turbine fuel shutoff valves
Closed
Ignition
OFF
Ventilation inlet air (secondary cooling air)
•
Fan
ON
•
Fan damper
Open
•
Fan bypass damper
Closed
Oil tank level
Full
Lube oil supply temperature
Water wash supply
Closed
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00510
31 May 2002
7.
PageS
MOTORING PROCEDURE.
a.
Dry (No fuel).
(I)
Complete prestart checks listed in table 2.
(2) Do not allow fuel to enter the gas turbine during dry motoring. If fuel flows into the gas turbine, purge fuel
by motoring the gas turbine for 60 seconds with no fuel flow (gas turbine shutoff valves shut). Be sure that during motoring
the fuel supply system is in operation to prevent the gas turbine fuel pump from running dry.
(3)
Motor gas turbine with starter to achieve maximum motoring speed.
(4)
Record:
(5)
(6)
•
Gas generator rotor speed (XN2)
•
Starter hydraulic supply pressure
•
Lube supply pressure.
Check for:
•
Fluid leaks
•
Unusual rubbing or scraping noises.
After motoring is complete. disengage starter and record gas generator (XN2) coastdown time. Check for
unusual noises.
b.
Wet.
(I)
Complete prestart checks listed in table 2.
I CAUTION]
Ensure that the ignition circuit remains deactivated during
this procedure.
(2)
Motor gas turbine with starter to achieve maximum motoring speed.
(3)
When speed has stabilized, open gas turbine fuel shutotT valves.
(4)
When fuel manifold pressure stabilizes. record:
(5)
•
Fuel manifold pressure
•
Gas generator rotor speed (XN2)
•
Starter hydraulic supply pressure
•
Lube supply pressure
•
Fuel supply temperature.
Close gas turbine fuel shutoff valves.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00510
31 May 2002
(6)
8.
Page9
Check for:
•
Fluid leaks
•
Unusual rubbing or scraping noises.
(7)
Continue motoring for 60 seconds to purge fuel.
(8)
Disengage starter and record gas generator (XN2) coastdown time. Check for unusual noises.
STARTING PROCEDURE.
a.
Perform prestart checks listed in table 2.
b. The following constraints are imposed during the start to protect the gas turbine. If any of these constraints are
violated, abort the start sequence immediately:
(I)
(2)
shutoff valves.
(3)
c.
Gas generator rotor (XN2) must reach 1,200 rpm within 5 seconds after energizing the starter.
Power turbine inlet temperature (T4.8) must reach 392°F (200°C) within 40 seconds after opening the fuel
Gas generator rotor (XN2) must reach 9,500 rpm within 45 seconds after energizing starter.
For normal startup. the following sequence of events must be adhered to:
(I)
Reset alarms and switches.
(2)
Energize starter.
(3)
At gas generator rotor speed (XN2) of 1,200 rpm do the following:
(4)
(5)
(a)
Energize ignition system.
(b)
Open fuel shutoff valves.
At gas generator rotor speed (XN2) of 9,500 rpm do the following:
(a)
De-energize ignition system.
(b)
De-energize starter.
When gas turbine is at idle. set control system for normal operation.
(6) Prior to accelerating above idle, ensure that all gas turbine parameters are in the normal operating range
and no out-of-limit conditions exist.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00510
Page 10
31 May 2002
9.
NORMAL OPERATION.
a.
Adhere to normal operating ranges and limits of table I.
b. Ventilation inlet air (secondary cooling) to the gas turbine compartment must be aligned based on gas turbine
operating condition, as follows:
Operating Condition
Fan Damper
Eductor Damper
Power Turbine Rotor
Speed (XNSD) 5,500 rpm
ON
Open
Closed
Power Turbine Rotor
Speed (XNSD) 5,500 rpm
OFF
Open
Open
Fire/Emergency
Shutdown
OFF
Closed
Closed
10.
ABNORMAL RUNNING CONDITIONS.
a.
General.
(I)
If an abnormal gas turbine condition occurs, such as compressor stall. flameout, or overtemperature. shut
down gas turbine. Record duration and degree of any abnormal condition. (Refer to table I for limits.)
(2) In most cases, continued operation of the gas turbine is permitted if the operator has been able to restore the
gas turbine parameters within limits from an alarm or abnormal condition. Troubleshooting must be conducted at the earliest
opportunity to find the cause of the problem, so as to preclude its reoccurrence during later operation. Causes of abnormal
operation may involve complex control logic and/or interactions between several systems. Ensure that adequate corrective
action has been taken prior to further operation.
b.
Overtemperature.
CAUTION
Do not operate gas turbine until cause of overtemperature
has been determined. An overtemperature inspection may
be necessary.
(I)
(2)
An overtemperature condition exists and requires an overtemperature inspection if:
(a)
During starting, T4.8 increases rapidly above 1.600°F (871 °C) immediately after lightoff.
(b)
After gas generator rotor reaches 8.900 rpm and T4.8 exceeds limits given in table I.
If an overtemperature condition exists, troubleshoot (WP 006 I 0).
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GEK 99441
00510
31 May 2002
c.
Page 11
Overspeed.
CAUTION
Do not operate gas turbine until cause of overspeed has been
determined and corrective action taken; otherwise, gas turbine damage may occur.
(I)
If gas generator speed or power turbine output shaft speed exceeds the limits given in table I. or an overspeed trip occurs, shut down gas turbine.
(2)
d.
If operating limits have been exceeded. troubleshoot (WP 006 10).
Abnormal Vibrations.
(I)
High vibrations can be caused by rotor imbalance and by loose gas turbine mounts or other external connections. If operating limits have been exceeded, troubleshoot (WP 006 I 0).
(2) Occasionally, it may be noted that vibrations increase as much as 3 mils after a shutdown of I to 2 hours.
The most probable cause is a temporary thermal rotor bow due to uneven cooling of the power turbine or gas generator rotors.
If the shutdown is brief (less than I 0 minutes) or long (more than 6 hours). thermal rotor bow is controlled because the rotors
cool either very little or to a uniform temperature.
(3) A thermal rotor how can be identified by noting that the increased vibration levels gradually decrease to
previous levels during approximately I 0 minutes of gas turbine operation. As long as vibrations are decreasing with time, gas
turbine operation may be continued even if some limits are temporarily exceeded.
e.
Compressor Stall.
(I) A compressor stall is caused by an aerodynamic disturbance of the smooth airf1ow pattern through the
compressor. A rapid increase of T4.8 and usually a speed hangup (although some stalls are accompanied by a rapid decrease
in speed) are indications of a stall. A change in gas turbine noise level may also be noted.
(2)
If a stall occurs. do the following:
(a)
Shut gas turbine down immediately.
I CAUTION I
Do not attempt a restart after a stall until cause has been
investigated.
(b)
f.
If operating limits have been exceeded, troubleshoot (WP 006 I 0).
Hot Start.
(I) If during a start T4.8 increases abnormally, shut the gas turbine down immediately and record highest
observed T4.8. (Refer to table I to determine if operating limits have been exceeded.)
(2)
If operating limits have been exceeded, troubleshoot (WP 006 I 0).
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GEK 99441
00510
Page 12
31 May 2002
g.
h.
1.
11.
Flameout.
(I)
Shut down gas turbine (para 12).
(2)
If operating limits have been exceeded. troubleshoot (WP 006 10).
Abnormal Oil Pressure.
(I)
Do not operate gas turbine if stabilized oil pressure is outside the limits given in table I.
(2)
If limits are exceeded, troubleshoot (WP 006 10).
Abnormal Fuel Flow.
(I)
Fuel flow is abnormal if it does not meet the operating limits given in table I.
(2)
If operating limits have been exceeded. troubleshoot (WP 006 I 0).
NORMAL SHUTDOWN PROCEDURE.
a.
The normal shutdown procedure must be used for all gas turbine shutdowns. except for those requiring instant
shutdown to prevent significant damage.
b.
For normal shutdown. the following sequence of events must be adhered to:
(I)
Set throttle to idle.
(2)
Run gas turbine at idle for 5 minutes.
(3)
After 5 minutes at idle, de-energize fuel shutoff valves.
(4) IfT4.8 does not decrease below 392oF (200°C) within 90 seconds. investigate for failure to stop.
If T4.8 exceeds l,OOOoF (538°C), take action for post-shutdown fire as follows:
(5)
(a)
Ensure fuel shutoff valves are de-energized (closed).
(b)
Motor gas turbine with starter until T4.8 decreases to 600°F (316°C) or less.
Shut down gas turbine support systems as required.
12. EMERGENCY SHUTDOWN PROCEDURE. An emergency shutdown occurs when the control system shutdown
trip is experienced or when the fuel shutolf valves are de-energized prior to a 5-minute idle period. The following procedures
must be followed after an emergency shutdown:
a.
Observe instrumentation for cause of shutdown.
b.
Shut off ventilation fan to prevent irregular exterior cooling.
c.
If rotor coastdown appeared normal, motor gas turbine for 2 minutes and check for abnormalities.
d.
Troubleshoot (WP 006 I 0) and determine cause of shutdown.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
Page 1 of 26
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TROUBLESHOOTING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G02
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Abnormal Acceleration to Max Power ...................................................
Abnormal Deceleration from High Power ................................................
Consumable Materials ................................................................
Flameout ..........................................................................
Gas Turbine Does Not Reach Idle or Slow Acceleration to Idle ................................
High Power (Steady-State) Problems ....................................................
High Vibrations .....................................................................
Hot Start (Starting Stall) ..............................................................
Idle Speed Problems .................................................................
Instrumentation Requirements .........................................................
Introduction ........................................................................
Lubrication System Problems ..........................................................
No Start (NoN I Indication) ...........................................................
No Start (With NI Indication) ..........................................................
Overspeed/Overtemperature ...........................................................
Post-Shutdown Fire ..................................................................
Support Equipment ..................................................................
Troubleshooting Instructions ...........................................................
1.
Page No.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
11
13
2
16
8
13
23
8
9
2
16
7
5
24
24
2
INTRODUCTION.
a.
The troubleshooting work package consists of tables that list symptoms, possible cause, troubleshooting, and
corrective action for each type of problem. Gas turbine operating limits and remarks are given in WP 005 00.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
b.
The following symbols are used in the troubleshooting section:
AGB
Accessory Gearbox
CIT
Compressor Inlet Temperature (Tl.S)
FOD
Foreign Object Damage
HPT
High-Pressure Turbine or
Gas Generator Turbine
NI
Compressor Gas Generator Rotor Speed
(rpm)
N2
Power Turbine Shaft Speed (rpm)
2.
Page2
PS or
PS3
Compressor Discharge Static Pressure
PTO
Power Takeoff (inlet gearbox)
SOAP
Spectrometric Oil Analysis Program
T4.8
Power Turbine Inlet Total Temperature
VG
Variable Geometry
vsv
Variable Stator Vanes
Wf
Fuel Flow Delivery from the Fuel Valve
SUPPORT EQUIPMENT.
Support Equipment
3.
Part No.
NomenclatureNomenclature
2C9111GOI
Borescope Kit
CONSUMABLE MATERIALS.
None
4.
INSTRUMENTATION REQUIREMENTS.
Compressor Inlet Temperature (T 1.5)
-40° to 150°F (-40° to 66°C)
Compressor Discharge Static Pressure (PS3)
0 to 300 psi (0 to 2.068 kPa)
Fuel Supply Pressure
0 to 400 psi (0 to 2,758 kPa)
Fuel Supply Temperature
-65" to ISO"F (-54 o to 66°C)
Fuel Manifold Pressure
0 to 300 psi (0 to 2.068 kPa)
Variable Stator Vane Angle
19 to 67 degrees
Oil Tank Temperature
Lube and VG Control Oil Inlet Temperature
oo to 300"F (-18" to 1500C)
oo to 300°F (-18° to 150°C)
Power Turbine Inlet Pressure (PT4.8)
0 to 75 psi (0 to 517 kPa)
Power Turbine Inlet Temperature (T4.8)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00600
GEK 99441
31 May 2002
5.
Page3
TROUBLESHOOTING INSTRUCTIONS.
a. If the gas turbine does not operate properly. refer to table l and locate the category which applies to the phase of
operation during which the trouble occurred (for example, NO START- WITH NI INDICATION). If the gas turbine is operating outside its limits, refer to the appropriate category (for example. LUBRICATION SYSTEM PROBLEMS).
b.
Follow the sequence of checks outlined in the referenced paragraph.
c. If the checks indicate that a component is defective, replace the component. Test the gas turbine based on which
component has been replaced.
d. Certain conditions may cause gas turbine damage. Refer to WP 016 00, paragraph entitled Special Inspections
of Gas Turbine. in addition to the procedures in this work package.
e.
Operation of the gas generator with variable stator vanes significantly out of limits can damage the gas turbine.
When troubleshooting for abnormal speed. compressor stall, low power. or abnormal acceleration problems, ensure that precautions contained in WP 012 00 are observed.
TABLE 1.
TROUBLESHOOTING INDEX
Symptom
Paragraph No.
NO START (WITH NI INDICATION)
6
A.
B.
C.
RPM and fuel tlow OK
RPM and ignition OK but no or low fuel manifold pressure
NI rises rapidly to starter cutout speed (58%)
NO START (NO NI INDICATION)
7
A. NoN I indication (with oil pressure indication)
B. NoN I indication (without oil pressure indication)
HOT START (STARTING STALL)
8
Gas turbine stalls during start. Slow increase in T4.8 plus NI speed hangup or
dropoff
GAS TURBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE
9
No or slow acceleration to idle speed accompanied by low fuel flow and low T4.8
IDLE SPEED PROBLEMS
A.
B.
C.
D.
E.
F.
G.
NoN I indication (with oil pressure)
NoN I indication and no oil pressure indication
Idle speed low
Idle speed high
Instability
Power turbine rotation without display indication
No power turbine rotation
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
10
006 00
GEK 99441
Page4
31 May 2002
TABLE 1.
TROUBLESHOOTING INDEX (Cont)
Symptom
Paragraph No.
ABNORMAL ACCELERATION TO MAX POWER
A.
B.
C.
D.
E.
11
No acceleration
Slow acceleration with low T4.8
Slow acceleration with high T4.8
Compressor stall
NI or T4.8 overshoot at base load
ABNORMAL DECELERATION FROM HIGH POWER
12
A. Flameout or low NI
B. Compressor stall
HIGH POWER (STEADY STATE) PROBLEMS
A.
B.
C.
D.
13
Low N2 in AUTO mode
RPM fluctuation or T4.8 fluctuation in AUTO control mode
Higher or lower T4.8 than previous reading at max
Stall during steady-state operation
FLAME OUT
14
Low or no fuel manifold inlet pressure indication
LUBRICATION SYSTEM PROBLEMS
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
15
Gas turbine oil tank contamination
No oil pressure
Low oil pressure
High oil pressure
Fluctuating oil pressure (greater than 5 psi (34 kPa))
Overfull oil tank
High oil temperature (oil appears as though it has been overheated)
Fluctuating oil temperature
High oil consumption
Exhaust fire and smoke
HIGH VIBRATIONS
16
A. Gas generator rotor vibration
B. Power turbine rotor vibration
POST-SHUTDOWN FIRE
After shutdown, T4.8 indicates 1,000°F (537°C) or higher
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
17
006 00
GEK 99441
PageS
31 May 2002
TABLE 1.
TROUBLESHOOTING INDEX (Cont)
Symptom
Paragraph No.
OVERSPEED/OVERTEMPERATURE
18
A.
B.
C.
6.
NI or T4.8 overshoot at max
Different NI than previous readings under same operating conditions
Higher T4.8 than previous reading at I 00% power under same operating conditions
NO START (WITH Nl INDICATION).
Possible Cause
Symptom
Troubleshooting
Corrective Action
I WARNING I
Disconnecting Ignition Leads
•
•
A.
RPM and fuel
flow OK.
High voltage may be present. Contact with center conductor of electrical cable
or cent er electrode of igniter plug will cause electric shock if the bleed resistors
inside ignition unit have failed.
Before removing igniter plug, be sure that discharge connector is grounded.
I.
Faulty igniter circuit.
a.
b.
Disconnect ignition leads
at ignition exciter, check
resistance of ignition
leads, plug adapters and
igniter plugs. Resistance
to ground should be
I00.000 ohms or more. If
resistance is low, check
individual components.
Disconnect power
connector at ignition
exciter. Check resistance
from pins A to C: 94 to
I 06 ohms required. Check
resistance from pins A to
B: 47 to 53 ohms required.
Check resistance from
pins B to C: 47 to 53 ohms
required.
Replace faulty components
(WP 023 00).
Replace faulty ignition
exciter (WP 023 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
006 00
31 May 2002
6.
Page6
NO START (WITH Nl INDICATION). (Cont)
Symptom
B.
RPM and
ignition OK
but no or low
fuel manifold
pressure.
Possible Cause
rapidly to
starter cutout
speed (58%).
Corrective Action
c.
Check for 115V. 50 to 60Hz
at power lead connection.
Restore power.
d.
Disconnect output
connection at ignition
exciter. Check resistance
of outputs to ground.
Resistance must be 590 to
610 ohms.
Replace ignition exciter
(WP 023 00).
2.
Eroded igniter plugs
(usually caused by
leaving ignition switch
ON for extended
periods of time).
With ignition switch turned
ON.Iisten for igniter plug
clicking.
Replace igniter plugs
(WP 023 00).
I.
No fuel flow supply.
Check shutoff valve positions.
Open the fuel inlet
valve(s).
2.
Air. water. or solids
in fuel lines.
Disconnect fuel supply lines,
and check for presence of air
or contaminant.
a.
Bleed the air from
supply lines.
b.
Blow air in supply
lines to flush liquid or
solid contaminant.
3.
C. NI rises
Troubleshooting
Failure of fuel shutoff
valves.
Sheared radial drive
shaft. PTO gear, or
AGB input gearing.
Check that shutoff valves are
energized.
Troubleshoot as required.
Crank gas turbine from pad
on AGB. Check for compressor or HPT rotation using
borescope 2C91 I I GO I
through compressor or
combustor port.
Isolate and replace
defective drive
component
(WP 032 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
7.
Page7
NO START (NO NI INDICATION).
Symptom
A.
NoNI
indication
(with oil
pressure
indication).
Possible Cause
NI indication failure.
Troubleshooting
Check GG speed sensors.
indicator. and electrical leads.
Check AGB to verify rotation
of crank pad.
Corrective Action
Replace speed sensors.
indicator. electrical leads.
or sensor wheel as
required (WP 026 00).
CAUTION
Do not operate gas turbine for more than 30 seconds without oil pressure or
damage to gas turbine could result.
B.
NoNI
indication
(without oil
pressure
indication).
I.
Starter pressure
below limits
Check starter supply pressure
(refer to WP 005 00 for limits).
Increase pressure to
proper limit. or replace
starter if pressure is OK.
2.
Faulty start selector
switch or open circuit
breaker( s).
Check start selector switch
and circuit breaker(s).
Replace switch and/or
reset circuit breakers.
3.
Starter inoperative.
Check starter.
Replace starter if it does
not rotate, if it cuts out
early, or if drive clutch or
shaft is faulty.
4.
Gas generator
SeiZUre.
a.
Allow hot gas turbine to
cool for 30 minutes, and
check gas generator
rotation with starter or
with ratchet wrench on
AGB crank pad.
Attempt another start
after cooling period and
rotation check.
b.
Check cold gas turbine
rotation with ratchet
wrench on AGB crank
pad.
(I) Replace gas turbine
if wrench cannot
rotate gas turbine.
(2) Replace radial drive
shaft. power takeoff,
or accessory gearbox
(WP 032 00) if
wrench turns but gas
turbine does not
rotate.
c.
Borescope-inspect
(WP I 0 00) gas turbine
at compressor inlet and
stage I 0 port for FOD.
Remove gas turbine for
repair of FOD if noted.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 8
31 May 2002
7.
NO START (NO Nl INDICATION). (Cont)
Symptom
Possible Cause
5.
8.
Corrective Action
Rotate gas generator using AGB
crack pad.
Replace gearbox
(WP 032 00). Flush scavenge
drain system and lube oil tank
as necessary to remove
contaminants.
Troubleshooting
Corrective Action
HOT START (STARTING STALL).
Symptom
Gas turbine stalls
during start. Slow
increase in T4.8
pi us NI speed
hangup or dropoff.
Possible Cause
I.
2.
9.
Accessory gearbox failure.
Troubleshooting
Variable stator vanes
position is incorrect.
Fuel pressure
irregular.
Check variable stator vanes
position while motoring gas
turbine (should be 62-64
degrees).
Check PS3 sensor and line
(customer equipment) for
leaks.
a.
Check VG feedback
cable for binding and
interference.
b.
Re-rig VG feedback
cable (WP 012 00).
Repair or replace
defective component.
GAS TIJRBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE.
Symptom
Possible Cause
Troubleshooting
Corrective Action
I CAUTION I
Do not exceed starter duty cycle.
No or slow
acceleration to idle
speed accompanied
by low fuel tlow
and low T4.8.
1.
Low starter pressure.
Check starter hydraulic oil
pressure. It should be
3.000 psig (20.684 kPa)
and gas turbine should
rotate at 28-34% NI
minimum.
Increase pressure to
proper limit.
2.
Starter cutout speed
too low.
Check rpm at which starter
cuts out. It should cut out at
58lk Nl.
Troubleshoot starter.
control valves, and starter
drive clutch.
3.
Fuel contamination.
Check for filter bypass
indication.
Blow down fuel system.
Clean or replace all fuel
filters. Reset bypass
indicator.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
9.
Page9
GAS TURBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE. (Cont)
Symptom
Possible Cause
4.
Variable stator vanes
position is incorrect.
Troubleshooting
a.
b.
10.
Corrective Action
Check variable stator
vanes position while
motoring gas turbine
(should be 62-64 degrees).
(I) Re-rig VG feedback
Check for excessively
worn VSV linkage or
improper stage-to-stage
rigging.
Correct rigging of VSV
linkage assembly
(WP01200).
cable (WP 012 00).
(2) Check for binding
and interferences
using pull check.
Pull check should be
I 0 pounds (4.5 kg)
with cable connected.
4 pounds ( 1.8 kg) with
cable disconnected.
maximum.
5.
P3 tube leakage or
defective transducer.
Check for loose, damaged, or
blocked tube, and loss of
electrical signal to control.
Tighten or replace tube,
replace transducer. or
electrical lead.
6.
Compressor/high
pressure turbine rotor
rubbing excessively.
Borescope-inspect (WP 0 I 0 00)
gas turbine. Look for rolled
material on blade tip. This indicates heavy rub.
Replace gas turbine.
IDLE SPEED PROBLEMS.
Symptom
Possible Cause
Troubleshooting
Corrective Action
I CAUTION I
Do not operate gas turbine for more than 30 seconds without oil pressure or damage to gas turbine could result.
A. NoNI
indication
(with oil
pressure
indication).
Indicator or harness
failure.
Check harness and indicator.
Replace faulty
component.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 10
31 May 2002
10. IDLE SPEED PROBLEMS. (Cont)
Symptom
Possible Cause
B.
NoN!
indication and
no oil pressure
indication.
Loss of signal.
c.
Idle speed
low.
I.
D. Idle speed
high.
E.
Instability.
Troubleshooting
Corrective Action
Immediately shut gas turbine
down. Check pump. transducer,
indicator. piping and cabling.
Repair or replace faulty
component.
VG control CIT
sensor failure.
Check stator vanes position at
idle.
Replace VG control
assembly (WP 028 00).
2.
P3 tube leakage,
blockage. or defective
transducer.
Check for loose. damaged, or
blocked tube.
Tighten or replace tube
or replace transducer
3.
Faulty speed
indication.
a.
Check indicator for
accuracy.
Replace indicator.
b.
Check gas generator
speed sensor(s).
Replace sensor
(WP026 00).
a.
NI rises to 70 to 857c.
depending on accessory
loads.
Replace VG control
assembly (WP 028 00).
b.
N2low.
c.
Stator vanes fully closed.
I.
VG control drive
shaft failure.
2.
Faulty speed
indication.
Check indicator for accuracy.
Recalibrate or replace
indicator.
3.
P3 tube leakage.
Inspect fittings for looseness.
Tighten fittings.
I.
Air in gas system.
Advance power and return to
idle.
Recheck for stability at
idle.
2.
VG control CIT
sensor failure.
Check CIT sensor bulb and
capillary tube for damage.
Replace VG control
assembly (WP 028 00).
3.
VG feedback cable is
binding.
Disconnect VG feedback
cable and do a pull check.
Pull check should be
I 0 pounds (4.5 kg) when
connected. 4 pounds ( 1.8 kg)
when disconnected.
Replace VG feedback
cable (WP 028 00).
4.
Intermittent NI
output.
Check gas generator speed
sensors and output leads.
Replace defective
component (WP 026 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
Page 11
10. IDLE SPEED PROBLEMS. (Cont)
Symptom
F.
G.
Power turbine
rotation
without display
indication.
No power
turbine
rotation.
Possible Cause
I.
Faulty rpm indication.
Troubleshooting
Corrective Action
a.
Visually check power
turbine rotation by
observing shaft rotation
through coupling guard
access cover.
Verify rotation.
b.
Check indicator. power turbine speed sensors.
and harnesses.
Replace faulty component
(WP 027 00).
I.
Failure of. or foreign
object lodged in. gas
compressor connected
to gas turbine.
Visually inspect gas compressor
through inlet or discharge
flanges.
Repair or replace faulty
component.
2.
Power turbine blade/
shroud or interstage
seal seizure.
Allow gas turbine to cool for
2 hours and then attempt to
rotate.
Repair or replace gas
turbine.
I CAUTION I
Do not exceed IDLE power or damage to gas turbine may occur.
3.
11.
Wear-in of new
shrouds and seals on
initial startup.
(Probable cause if
turbine is free to
rotate when cold.
Operate gas turbine at idle
speed for 5 minutes. Shut gas
turbine down if power turbine
does not rotate.
Allow gas turbine to cool
down until power turbine
is free, and repeat start.
ABNORMAL ACCELERATION TO MAX POWER.
Symptom
Possible Cause
Troubleshooting
Corrective Action
A.
No
acceleration.
Compressor discharge
pressure system leak.
blockage. or transducer
failure.
Check for loose. damaged, or
blocked lines.
Tighten or replace lines.
or replace PS3 transducer.
B.
Slow
acceleration
with low T4.8.
I.
Check inlet pressure.
Troubleshoot per paragraph 14
(Flameout).
Low fuel inlet
pressure.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 12
31 May 2002
11. ABNORMAL ACCELERATION TO MAX POWER. (Cont)
Symptom
c.
Slow
acceleration
with high
T4.8.
D. Compressor
stall.
Possible Cause
Corrective Action
Troubleshooting
2.
Compressor discharge
pressure system leak.
blockage. or transducer
failure.
Check for loose, damaged,
or blocked lines. and PS3
output.
Tighten or replace lines.
or replace sensor.
I.
Foreign object
damaged.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Replace gas turbine if
FOD exceeds limits.
2.
Variable stator vanes
schedule failure.
Check variable stator vanes
schedule (WP 012 00). Check
for binding VSV actuator or
linkage assembly.
a.
Re-rig VG feedback
cable (WP 012 00).
b.
Replace VG
control assembly
(WP 028 00).
c.
Repair linkage
assembly
(WP029 00).
3.
Dirty compressor.
Borescope-inspect (WP 010 00)
gas turbine or check gas generator pressure ratio.
Water-wash compressor
(WP 017 00).
I.
VG feedback cable
is binding.
Disconnect VG feedback
cable and do a pull check.
Pull check should be
10 pounds (4.5 kg) when
connected, 4 pounds ( 1.8 kg)
when disconnected.
Replace VG feedback
cable (WP 028 00).
2.
Variable stator vanes
schedule failure.
Check variable stator vanes
schedule (WP 012 00).
Re-rig VG feedback
cable (WP 012 00).
3.
VG control CIT
sensor failure.
Check sensor.
Clean sensor (WP 009 00)
or replace VG control
assembly (WP 028 00).
4.
Stator vane lever arm
broken or disconnected.
Check to see that all vane
lever arms are engaged in
holes of actuator rings.
If any lever arms are
broken or disconnected.
contact GE for assistance.
5.
Foreign object
damage.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Replace gas turbine if
FOD exceeds limits.
6.
VG control assembly
defective.
Inspect VG control
assembly (WP 028 00).
Replace VG control
assembly (WP 028 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00600
31 May 2002
Page 13
11. ABNORMAL ACCELERATION TO MAX POWER. (Cont)
Symptom
E.
NI or T4.8
overshoot at
base load.
Possible Cause
I.
2.
12.
Variable stator vanes
are not fully open.
Faulty Nlff4.8
indications.
NI reaches 99-100% but
T4.8 and N2 remain low.
Check indicator systems.
Corrective Action
a.
Check for free travel
of stator system.
b.
Check rigging of VG
feedback cable
(WP 012 00).
c.
If problem persists,
replace VG control
assembly (WP 028 00).
Repair or recalibrate
indicators.
ABNORMAL DECELERATION FROM HIGH POWER.
Symptom
Possible Cause
A.
Flameout
or low NI.
Leaking P3 tube to PS3
sensor connection.
B.
Compressor
stall.
I.
2.
13.
Troubleshooting
Troubleshooting
Corrective Action
Slow starts and slow
acceleration with low T4.8.
Repair or replace
P3 tube or PS3 sensor.
VG feedback cable
is binding.
Disconnect both ends of VG
feedback cable and check for
free travel. Pull check should
be 4 pounds (1.8 kg) maximum.
Replace VG feedback
cable (WP 028 00).
VG control feedback
lever defective.
Check for free travel
of lever.
Replace VG control
assembly (WP 028 00).
HIGH POWER (STEADY-STATE) PROBLEMS.
Symptom
A. Low N2 in
AUTO mode.
Possible Cause
I.
Excessive output
shaft torque
(T4.8 limiting).
Troubleshooting
Corrective Action
a.
Check torque.
Reduce.
b.
Check for possible
compressor discharge air
leak at capped stage I 0 or
stage 14 bleed ports, or
leak in sump pressurization
air lines.
Eliminate leakage.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 14
31 May 2002
13. HIGH POWER (STEADY-STATE) PROBLEMS. (Cont)
Symptom
B.
Possible Cause
Troubleshooting
Corrective Action
2.
Dirty compressor.
Check performance (gas
turbine pressure ratio) or
borescope-inspect
(WP 010 00).
Water-wash gas turbine
(WP 017 00).
3.
Low fuel flow.
a.
Check P3 tube and
transducer.
Replace tube or
transducer.
b.
Check VG schedule
(WPOI200).
Replace VG control
assembly (WP 028 00).
RPM fluctuation or T4.8
fluctuation in
AUTO control
mode.
NOTE
Fluctuation of a single instrument, without similar
fluctuation of related instruments, indicates instrument
malfunction.
I.
Faulty NI/Wf!T4.8
indicators.
Check indicators for accuracy.
Replace faulty indicator.
2.
VG feedback cable
is binding.
Disconnect VG feedback
cable and check for free
travel.
Replace VG feedback
cable (WP 028 00).
3.
Fuel supply system
defective.
a.
Check fuel header
pressure.
Correct as required.
b.
Check emergency shutoff
valve for full open
position.
Reposition or replace
valve.
4.
Oxidized electrical
connectors.
Check T4.8 harness electrical
connectors for contamination/
oxidation.
Clean electrical connectors or
replace harness.
5.
Compressor discharge
pressure system leak.
Check for loose or damaged
compressor bleed blankoff
plates or leakage in sump
pressurization lines.
Correct as required.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 15
31 May 2002
13. HIGH POWER (STEADY-STATE) PROBLEMS. (Cont)
Symptom
c.
Higher or
lower T4.8
than previous
reading at
max.
Possible Cause
I.
2.
D. Stall during
steady-state
operation.
Troubleshooting
Corrective Action
If all other readings
are the same as those
previously taken at
rated load:
a.
Faulty indicator.
Check T4.8 input and
indicator for accuracy.
Replace indicator.
b.
Faulty T4.8
harness.
Measure harness pin-to-pin
and pin-to-ground resistance.
Replace faulty harness.
If all other readings
changed with T4.8:
a.
Dirty compressor
blades.
Borescope-inspect compressor
(WP 010 00).
Water-wash gas turbine
(WPOI700).
b.
CIT sensor
failure.
Check CIT sensor.
Replace CIT sensor
(WP 009 00).
c.
Foreign object
damaged.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Replace gas turbine if
FOD exceeds limits.
d.
VG control
assembly is
defective.
Inspect VG control
assembly (WP 028 00).
Replace VG control
assembly (WP 028 00).
Check that all vane lever
arms are properly engaged
in actuator rings.
If any lever arms are
broken or disconnected.
contact GE for assistance.
I.
Disengaged or broken
vane lever arms.
2.
Inlet screen is
restricted by:
a.
Ice.
(I) Melt ice with portable
heater. Borescope-inspect
(WP 0 I0 00) gas turbine
for FOD caused by ice
formation on IGV's.
Replace gas turbine if
FOD exceeds limits.
b.
Foreign objects
(except ice).
(2) Remove objects restricting
inlet screen. Borescope gas
turbine if any deterioration
in screen integrity is found
or there is possibility that
objects passed through
screen into compressor.
Replace gas turbine if
FOD exceeds limits.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
Page 16
13. HIGH POWER (STEADY-STATE) PROBLEMS. (Cont)
Symptom
14.
Possible Cause
Corrective Action
3.
Incorrect variable
stator vanes position.
Check variable stator vanes
schedule (WP 012 00).
Re-rig VG feedback
cable (WP 012 00).
4.
Foreign object
damage.
Borescope-inspect gas
turbine (WP 010 00).
Replace gas turbine if
FOD exceeds limits.
FLAMEOUT.
Symptom
Low or no fuel
manifold pressure
indication.
Possible Cause
Troubleshooting
Corrective Action
I.
Contamination.
2.
Incorrect variable
stator vanes position
if tlameout happened
during compressor
stall.
Check variable stator
vanes schedule
(WPOI200).
P3 sensing line
transducer is
leaking.
a.
Inspect line for leaks
or looseness.
Tighten or replace line.
b.
Check operation and
calibration of transducer.
Recalibrate or replace
transducer.
3.
15.
Troubleshooting
Blow air in gas supply
lines to remove contaminants.
a.
Re-rig VG feedback
cable (WP 012 00).
b.
Replace VG control
assembly (WP 028 00).
LUBRICATION SYSTEM PROBLEMS.
Symptom
Possible Cause
Troubleshooting
A. Oil tank is
contaminated.
Maintenance error/
abnormal SOAP
sample.
If gas turbine operated for
B.
I.
Check for NI indication
while motoring gas turbine.
Verify lube supply to pump.
Nooil
pressure.
Sheared pump
shaft.
200 hours or more with
MIL-L-23699 oil containing
more than 59c mineral oil.
remove C-sump cover and
inspect for excessive coking
and deposits.
Corrective Action
Service lube system
(WP 019 00).
Replace pump (WP 031 00)
if there is no oil pressure with
an NI indication and normal
oil supply to pump.
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 17
31 May 2002
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
2.
Low oil level
in tank.
Check for source of abnormal
oil loss such as a loose connection. a crack in line or in a tank
weld. a failed pump seal, an
open SOAP sampling cock. or a
loose drain fitting. Check for oil
carryover to gas turbine through
tank vent line to compressor
front frame.
Correct the problem.
3.
Faulty oil pressure
indication.
Check indicating system
for faulty circuits.
Replace faulty
component.
4.
Faulty transmitter
or pressure line.
Check transmitter for open
circuit or for loose or
broken pressure line.
Replace faulty
component.
5.
Obstruction in oil
supply line to pump.
a.
Disconnect supply line at
pump, and check for
presence of oil.
Correct the problem.
b.
Check oil supply
hose for deterioration
(collapsed.)
Replace oil supply
hose (WP 031 00).
c.
Check for obstruction
in pump inlet.
Remove obstruction from
pump and clean oil tank.
d.
Check for improperly
connected lines or
reversed check valve.
Correct the problem.
6.
C.
Corrective Action
Troubleshooting
Possible Cause
Inlet screen in tank
(for pump supply
line) obstructed.
Remove inlet screen and
check for obstructions.
Remove obstruction and
clean oil screen and tank.
Low oil
pressure.
NOTE
A decrease of I 0 psig (69 kPa) from the normal pressure
is cause for investigation. Do not operate gas turbine if
pressure is more than 15 psi (I 03 kPa) below minimum.
I.
With
fluctuation.
a.
Low oil level in tank.
Check oil level.
Refill oil tank to
correct level.
b.
External oil leak.
Inspect all external lines
and components for leaks.
Replace leaking component.
Torque loose fittings
(WP 031 00).
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
GEK 99441
006 00
Page 18
31 May 2002
15. LUBRICATION SYSTEM PROBLEMS. (Coni)
Symptom
Possible Cause
Troubleshooting
c.
Faulty oil pressure
indication.
Check indicating system
for accuracy.
d.
Tank pressure
fluctuation.
(I)
e.
Oil/water
contamination.
f.
Failure of pressure
relief valve in lube
and scavenge pump.
g.
Obstructed or
collapsed oil supply
hose to pump.
Check for worn scavenge
pump allowing too much
air in oil tank.
Replace pump
(WP031 00).
Correct the problem.
Check oil sample for milky
appearance or for dilution
with water. Pressure leakcheck oil tank if water is
found in oil.
(a) Repair source of
water entry into
tank.
(b) Service lube system
(WP 019 00).
Replace lube and
scavenge pump
(WP 031 00).
(I) Disconnect supply hose
at pump and check for
flow.
deterioration.
(3) Check for obstruction
in pump inlet.
Without
fluctuation.
Replace faulty
component.
(2) Check for carryover and
static lead of oil in tank
vent line.
(2) Check oil-in hose for
2.
Corrective Action
Replace supply hose
(WP 031 00).
Replace oil-in hose
(WP 031 00).
Remove obstruction
from pump.
a.
External oil leak.
Inspect for leaks.
Repair leak.
b.
Internal gas turbine
leak (possible
damaged oil seals).
Check for high oil
consumption.
Repair or replace
gas turbine.
c.
Faulty pressure
transmitter or cable.
Install another transmitter
to verify original pressure
readings. Check transmitter
for short circuit.
Replace transmitter
or cable.
D. High oil
pressure.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
15.
Page 19
LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
Possible Cause
Troubleshooting
Corrective Action
I CAUTION]
Do not operate gas turbine if oil pressure exceeds
30 psig (207 kPa) above normal pressure. after gas
turbine reaches stabilized temperature: otherwise,
damage to gas turbine may occur.
NOTE
•
•
An increase in oil pressure of I 0 psig (69 kPa) over
normal pressure is cause for investigation. Do not
replace the oil pump because it cannot be the cause
of high oil pressure.
Oil pressure during initial start (cold oil) should
return to normal after 5 minutes at IDLE speed, but
may take considerably longer under severe freezing
conditions. Higher power settings are required for
more rapid warm-up.
Operate gas turbine to
allow pressure to decrease
after warm-up.
I.
Low oil temperature
after warm-up.
2.
Faulty oil pressure
indication.
Check indicating system
for accuracy.
Replace faulty
component.
3.
Plugged oil filter.
Remove and inspect oil
filter (WP 019 00).
Service oil filter
(WP01900).
4.
Check valve, in oil
filter, is stuck.
5.
Blocked or kinked
oil tanks.
Inspect tubes for kinks or
blockage (WP 031 00).
Clean or replace faulty
tube (WP 031 00).
6.
Clogged oil tubes and
oil jets. (This is often
indicated by tendency
of pressure to creep
up.)
If oil filter was plugged but
the replacement oil filter did
not reduce the pressure to
within limits. remove and
inspect chip detectors
(WP 013 00) and record the
location where metal chips
and sludge were found.
Replace gas turbine.
7.
Restriction or
blockage in oil tank
vent line to gas
turbine.
Check for restriction.
Clean or replace faulty
component.
Replace oil filter
(WP 019 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
31 May 2002
Page 20
15. LUBRICATION SYSTEM PROBLEMS. (Cant)
Symptom
E.
Possible Cause
Corrective Action
Troubleshooting
Fluctuating oil
pressure
(greater than
5 psi (34 kPa)).
NOTE
Fluctuating oil pressure during transient conditions is
considered normal; however, these t1uctuations should
stop I minute after returning to steady-state conditions.
F.
Overfull oil
tank.
I.
Low oil level in tank.
Check oil level.
Refill oil tank to
correct level.
2.
Oil/water contamination.
Check oil sample for milky
appearance or for dilution
with water. Pressure-check oil
tank if water is found in oil.
a.
Repair source of
water entry into tank.
b.
Service lube system
(WP 019 00).
3.
Plugged oil filter.
Remove and inspect oil
filter (WP 019 00).
Service oil filter
(WP 019 00).
4.
Faulty oil pressure
transmitter.
Check transmitter
for accuracy.
Replace transmitter.
5.
Blocked or damaged
lube and scavenge
pump inlet hose.
a.
Disconnect inlet hose and
check for blockage or
damage.
Clean or replace hose
(WP 031 00).
b.
Inspect oil tank screen
for blockage.
Clean tank and screen.
6.
Failure of pressure
relief valve in lube
and scavenge pump.
7.
Defective oil tank
vent.
Remove cover and inspect
deaerator for cracks.
Repair or replace oil
tank.
8.
Defective oil pumpto-AGE drive pad
seal.
Check seal for oil leakage
or oil wetting.
Replace pump
(WP 031 00).
I.
Water in tank.
Check oil sample
(WP 015 00) for water.
a.
Determine and repair
source of water entry.
b.
Service lube system
(WP 019 00).
Replace lube and
scavenge pump
(WP031 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 21
31 May 2002
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
Troubleshooting
Possible Cause
2.
Incorrect servicing
procedure.
Added too much oil.
Corrective Action
Drain excess oil.
G. High oil
temperature
(oil appears as
through it has
been
overheated).
NOTE
Indication of overheated oil is apparent by extremely
dark oil in oil tank, by a pungent burned odor, by sludge
and varnish deposits on oil filter, or sludge on chip
detectors.
I.
Low oil level in tank.
Check oil level.
Re1ill oil tank to
correct level.
2.
Low oil tlow in
B- and/or C-sump,
resulting in high
scavenge temperature.
a.
Replace B- and C-sump
chip detectors (WP 013 00)
and thermocouple harness
(WP 025 00).
Record the sump area
that exceeded the limits.
and replace gas turbine.
b.
Operate gas turbine and
record B- and C-sump
scavenge oil temperature
and temperature at oil
cooler output. Max
allowable temperature at
ail/oil cooler oil output is
350°F ( I77°C).
c.
Subtract the temperature
at the air/oil cooler from
each of the B- and
C-sump scavenge temperatures. The resulting
differential temperature
should be below the
following limits:
B-sump: 160°F (71 °C)
C-sump: 130oF (54°C)
d.
Check for high or low oil
pressure.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
006 00
31 May 2002
Page 22
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
H. Fluctuating oil
temperature.
I.
Possible Cause
Faulty oil temperature
indicating system.
Corrective Action
Troubleshooting
Check indicating system
for accuracy.
Replace faulty
component.
High oil
consumption.
CAUTION
Do not operate gas turbine with fluctuating or below
limits oil pressure. A sudden increase in oil consumption
or a gradual increase over a period of time indicates
deterioration of the oil system and is cause for investigation.
I.
Records in error.
2.
Oil leaks in:
Exhaust fire
and smoke.
Correct records.
Replace hose. tube. or
fitting (WP 031 00).
a.
External hoses
and tubes.
Check all hoses, tubes.
and fittings for leaks.
b.
Accessory
gearbox.
I.
Check each gearbox pad
flange for leakage:
5 cc/minute normal
leakage during operation.
Replace defective parts.
2.
Check packings and seals
for damage.
Replace defective parts.
c.
J.
Verify records.
Oil pump.
Check oil pump seal drain:
5 cc/minute normal leakage
during operation.
Replace oil pump
(WP031 00).
3.
Plugged A-sump seal
drain tube (oil wetted
areas in coupling
guard).
Attach a tube to A-sump
drain tube and blow through
gently. Tube must have no
restrictions.
Clean (WP 031 00) drain
tube and orifice (from
6 o'clock front frame pad).
4.
Plugged seal pressure
tube to C-sump.
Attach a tube to C-sump tube
and blow through gently.
Tube must have no restrictions.
Clean (WP 03 I 00) tube
(from pressure regulating
valve to 12 o'clock strut
on exhaust frame).
5.
Internal gas turbine
damage.
Check oil filters. chip detectors.
and SOAP reports.
Replace gas turbine.
Fire or excessive smoke
observed in tailpipe.
Replace damaged C-sump
scavenge hose (WP 03 I 00).
Restricted or damaged
C-sump scavenge hose.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 23
31 May 2002
16.
HIGH VIBRATIONS.
Symptom
Corrective Action
Troubleshooting
Possible Cause
NOTE
•
•
A.
B.
Gas generator
rotor vibration.
Power turbine
rotor vibration.
Occasionally it may be noted that vibrations increase
as much as 3 mils after a shutdown of I to 2 hours.
The most probable cause is a temporary thermal
rotor bow due to uneven cooling of the power turbine
or gas generator rotors. If the shutdown is brief (less
than 10 minutes) or long (more than 6 hours),
thermal rotor bow cannot occur because the rotors
cool either very little or to a uniform temperature.
A thermal rotor bow can be identified by noting that
the increased vibration levels gradually decay back to
previous levels during approximately 10 minutes of
gas turbine operation. As long as vibrations are
decreasing with time, gas turbine operation may be
continued even if some limits are temporarily
exceeded.
I.
Faulty vibration
indicating system.
Check all connections and
vibration transducers for
looseness. Check leads for
chafing. Check indicators
for accuracy.
Replace faulty component
(WP024 00).
2.
Loose gas turbine
mounts.
Check gas turbine mounts
for security and alignment.
Realign and tighten
mounts.
3.
Foreign object
damage.
Borescope-inspect gas
turbine (WP 0 I0 00).
Replace gas turbine.
4.
Defective bearings.
a.
Refer to paragraph 15,
items B and C.
b.
Inspect oil filter
(WP 019 00) and chip
detectors (WP 013 00)
for debris.
Replace gas turbine.
c.
Check SOAP reports for
signs of impending
bearing failure.
Replace gas turbine.
5.
Dirty compressor.
I.
Faulty vibration
indicating system.
Water-wash compressor
(WP 017 00).
Check all connections and
vibration transducers for
looseness. Check leads for
chafing. Check indicators for
accuracy.
Replace faulty component
(WP 024 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
006 00
Page 24
31 May 2002
16. HIGH VIBRATIONS. (Cont)
Symptom
17.
Possible Cause
Loose gas turbine
mounts.
Check gas turbine mounts for
security and alignment.
Realign and tighten
mounts.
3.
Foreign object
damage.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Replace gas turbine.
POST-SHUTDOWN FIRE.
After shutdown,
T4.8 indicates
I ,000°F (537°C) or
higher.
B.
Troubleshooting
Possible Cause
Corrective Action
I.
High ambient
temperatures.
With ambient temperature at
100°F (38°C) or above, a T4.8
of I .000°F (537°C) or slightly
higher can be normal.
Motor gas turbine with
starter, ignition off. until
T4.8 indicates 600°F
(3 I 6°C) or less.
2.
Shutoff valves open.
Motor gas turbine and check
for fuel flow indication and
vapors. If present. check
shutoff valves.
Replace shutoff valves.
OVERSPEED/OVERTEMPERATURE.
Symptom
A.
Corrective Action
2.
Symptom
18.
Troubleshooting
NI or T4.8
overshoot
at max.
Different NI
than previous
readings under
same operating
conditions.
Troubleshooting
Possible Cause
I.
Corrective Action
If problem persists,
replace VG control
assembly (WP 028 00).
Variable stator vanes
are not fully open.
NI reaches 99-100%
but T4.8 and N2
remain low.
a.
Check for free travel of
variable stator system.
h.
Check rigging of VG
feedback cable
(WP 012 00).
2.
Faulty NI/T4.8
indications.
Check indicator systems.
Repair or recalibrate
indicators.
3.
Thermocouple
harness (open,
short circuit).
Inspect thermocouple
harness (WP 025 00).
Replace thermocouple
harness (WP 025 00).
I.
If all other readings
are the same as those
previously taken,
indicator may be
faulty.
Check indicator output.
Replace faulty
component.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
006 00
GEK 99441
Page 25/26
31 May 2002
18. OVERSPEED/OVERTEMPERATURE. (Cont)
Symptom
Possible Cause
2.
c.
Higher T4.8
than previous
reading at
100% power
under same
operating
conditions.
Troubleshooting
Corrective Action
If NI and N2 are
both low:
a.
Dirty compressor
rotor.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Water-wash gas turbine
(WP 017 00).
b.
Foreign object
damage.
Borescope-inspect gas
turbine (WP 0 I 0 00).
Replace gas turbine.
c.
Compressor
air leak.
Check sump pressurizing and
balance piston lines and port
blankolfs.
Eliminate leakage.
d.
Excessive power
extraction
(AGB).
Check for binding or abnormal
torque on AGB mounted components or for failure within AGB.
Replace defective
components
(WP 032 00).
3.
If NI increases and
N2 decreases. variable
vanes are misrigged
(closed).
Check variable vane
schedule (WP 012 00).
Re-rig VG feedback
cable (WP 012 00).
4.
If NI and N2
increase, the thermocouple harness has
failed.
Inspect thermocouple
harness (WP 025 00).
Replace thermocouple
harness (WP 025 00).
I.
If all other readings
are the same as those
previously taken.
indicator may be
faulty.
Check indicator output.
Replace faulty indicator.
2.
If all other readings
changed with T4.8:
a.
Variable stator
vanes off schedule.
Check VG feedback cable
for looseness (WP 012 00).
Adjust VG feedback
cable (WP 012 00).
b.
CIT sensor
failure.
Check CIT sensor.
Clean sensor (WP 009 00)
or replace VG control
assembly (WP 028 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 1 of 26
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TROUBLESHOOTING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G01 /-G03/-G04/
G05/-G06
MARINE GAS TURBINE
Alphabetical Index
Page No.
Subject
Abnormal Acceleration to Max Power ...................................................
Abnormal Deceleration from High Power ................................................
Consumable Materials ................................................................
Flameout ..........................................................................
Gas Turbine Does Not Reach Idle or Slow Acceleration to Idle ................................
High Power (Steady-State) Problems ....................................................
High Vibrations .....................................................................
Hot Start (Starting Stall) ..............................................................
Idle Speed Problems .................................................................
Instrumentation Requirements .........................................................
Introduction ........................................................................
Lubrication System Problems ..........................................................
No Start (No XN2 Indication) ..........................................................
No Start (With XN2 Indication) ........................................................
Overspeed/Overtemperature ...........................................................
Post-Shutdown Fire ..................................................................
Support Equipment ..................................................................
Troubleshooting Instructions ...........................................................
1.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
12
13
2
16
8
14
23
8
10
2
17
7
5
24
24
2
INTRODUCTION.
a.
The troubleshooting work package consists of tables that list symptoms, possible cause, troubleshooting, and
corrective action for each type of problem. Gas turbine operating limits and remarks are given in WP 005 I 0.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
b.
The following symbols are used in the troubleshooting section:
PS or
PS3
Compressor Discharge Static Pressure
PTO
Power Takeoff (inlet gearbox)
SOAP
Spectrometric Oil Analysis Program
T4.8
Power Turbine Inlet Total Temperature
Compressor Gas Generator Rotor
Speed
(rpm)
VG
Variable Geometry
vsv
Variable Stator Vanes
Power Turbine Shaft Speed (rpm)
Wf
Fuel Flow Delivery from the Fuel Valve
AGB
Accessory Gearbox
CIT
Compressor Inlet Temperature (TI.5)
FOD
Foreign Object Damage
HPT
High-Pressure Turbine or
Gas Generator Turbine
XN2
XNSD
2.
Page2
SUPPORT EQUIPMENT.
Support Equipment
3.
Part No.
Nomenclature
2C91111G01
Borescope Kit
CONSUMABLE MATERIALS.
None
4.
INSTRUMENTATION REQUIREMENTS.
Compressor Inlet Temperature (T 1.5)
Compressor Discharge Static Pressure (PS3)
0 to 300 psi (0 to 2,068 kPa)
Fuel Supply Pressure
5 to 55 psi (34 to 379 kPa)
Fuel Supply Temperature
-65° to 150°F (-54 o to 66°C)
Fuel Manifold Pressure
0 to 300 psi (0 to 2,068 kPa)
Variable Stator Vane Angle
19 to 67 degrees
Oil Tank Temperature
0° to 3l0°F (-18° to 155°C)
Lube and VG Control Oil Inlet Temperature
0° to 219oF (-18° to 104°C)
Power Turbine Inlet Pressure (PT4.8)
0 to 75 psi (0 to 517 kPa)
Power Turbine Inlet Temperature (T4.8)
oo to 1800°F (-18° to 1000°C)
oo to 350°F (-18° to I77°C)
Gas Turbine Scavenge Oil Temperature
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
5.
Page3
TROUBLESHOOTING INSTRUCTIONS.
a.
If the gas turbine does not operate properly. refer to table I and locate the category which applies to the phase of
operation during which the trouble occurred (for example. NO START- WITH XN2 INDICATION). If the gas turbine is
operating outside its limits. refer to the appropriate category (for example, LUBRICATION SYSTEM PROBLEMS).
b.
Follow the sequence of checks outlined in the referenced paragraph.
c.
If the checks indicate that a component is defective, replace the component. Test the gas turbine, based on which
component has been replaced.
d.
Certain conditions may cause gas turbine damage. Refer to WP 016 00, paragraph entitled Special Inspections
of Gas Turbine, in addition to the procedures in this work package.
e.
Operation of the gas generator with variable stator vanes significantly out of limits can damage the gas turbine.
When troubleshooting for abnormal speed, compressor stall. low power, or abnormal acceleration problems, ensure that precautions contained in WP 012 00 are observed.
TABLE 1.
TROUBLESHOOTING INDEX
Symptom
Paragraph No.
NO START (WITH XN2 INDICATION)
6
A. RPM and fuel flow OK
B. RPM and ignition OK but no or low fuel manifold pressure
C. XN2 rises rapidly to starter cutout speed (58%)
NO START (NO XN2 INDICATION)
7
A. No XN2 indication (with oil pressure indication)
B. No XN2 indication (without oil pressure indication)
HOT START (STARTING STALL)
8
Gas turbine stalls during start. Slow increase in T4.8 plus XN2 speed hangup or dropoff
GAS TURBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE
9
No or slow acceleration to idle speed accompanied by low fuel flow and low T4.8
IDLE SPEED PROBLEMS
A. No XN2 indication (with oil pressure)
B. No XN2 indication and no oil pressure indication
C. Idle speed low
D. Idle speed high
E. Instability
F. Power turbine rotation without display indication
G. No power turbine rotation
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
10
GEK 99441
00610
31 May 2002
Page4
TABLE 1.
TROUBLESHOOTING INDEX (Cant)
Symptom
Paragraph No.
ABNORMAL ACCELERATION TO MAX POWER
11
A. No acceleration
B. Slow acceleration with low T4.8
C. Slow acceleration with high T4.8
D. Compressor stall
E. XN2 or T4.8 overshoot at base load
ABNORMAL DECELERATION FROM HIGH POWER
12
A. Flameout or low XN2
B. Compressor stall
HIGH POWER (STEADY STATE) PROBLEMS
A.
B.
C.
D.
13
Low XNSD in AUTO mode
RPM fluctuation or T4.8 fluctuation in AUTO control mode
Higher or lower T4.8 than previous reading at max
Stall during steady-state operation
FLAME OUT
14
Low or no fuel manifold inlet pressure indication
LUBRICATION SYSTEM PROBLEMS
15
A. Gas turbine oil tank contamination
B. No oil pressure
C. Low oil pressure
D. High oil pressure
E. Fluctuating oil pressure (greater than 5 psi (34 kPa))
F. Overfull oil tank
G. High oil temperature (oil appears as though it has been overheated)
H. Fluctuating oil temperature
I. High oil consumption
1. Exhaust fire and smoke
HIGH VIBRATIONS
16
A. Gas generator rotor vibration
B. Power turbine rotor vibration
POST-SHUTDOWN FIRE
After shutdown. T4.8 indicates 527oF (275oC) or higher
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
17
00610
GEK 99441
PageS
31 May 2002
TABLE 1.
TROUBLESHOOTING INDEX (Cant)
Symptom
Paragraph No.
OVERSPEED/OVERTEMPERATURE
18
A. XN2 or T4.8 overshoot at max
B. Different XN2 than previous readings under same operating conditions
C. Higher T4.8 than previous reading at 1001r power under same operating conditions
6.
NO START (WITH XN2 INDICATION).
Symptom
Troubleshooting
Possible Cause
Corrective Action
I WARNING I
Disconnecting Ignition Leads
•
•
A.
High voltage may be present. Contact with center conductor of electrical cable
or center electrode of igniter plug will cause electric shock if the bleed resistors
inside ignition unit have failed.
Before removing igniter plug. be sure that discharge connector is grounded.
RPM and fuel flow
OK.
I.
Faulty igniter circuit.
a.
Disconnect ignition leads
at ignition exciter. check
resistance of ignition
leads. plug adapters and
igniter plugs. Resistance
to ground should he
I 00.000 ohms or more.
If resistance is low. check
individual components.
Replace faulty components (WP 023 00).
b.
Disconnect power connector at ignition exciter.
Check resistance from
pins A to C:
94 to I 06 ohms required.
Check resistance from
pins A to B:
47 to 53 ohms required.
Check resistance from
pins B to C:
47 to 53 ohms required.
Replace faulty ignition
exciter (WP 023 00).
c.
Check for I 15V.
50 to 60 Hz at power
lead connection.
Restore power.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
Page6
6. NO START (WITH XN2 INDICATION). (Cont)
Possible Cause
Symptom
Troubleshooting
d.
B.
RPM and ignition OK
but no or low fuel
manifold pressure.
XN2 rises rapidly to
starter cutout speed
(58%).
Replace ignition exciter
(WP 023 00).
2.
Eroded igniter plugs
(usually caused by leaving ignition switch ON
for extended periods of
time).
With ignition switch turned
ON. listen for igniter plug
clicking.
Replace igniter plugs
(WP023 00).
I.
No fuel flow supply.
Check shutoff valve
positions.
Open the fuel inlet
valve(s).
2.
Air, water, or solids in
fuel lines.
Disconnect fuel supply lines.
and check for presence of air
or contaminant.
a.
Bleed the air from
supply lines.
b.
Blow air in supply
lines to flush liquid or
solid contaminant.
c.
Clean fuel strainers.
3.
C.
Disconnect output connection at ignition
exciter. Check resistance
of outputs to ground.
Resistance must be
590 to 61 0 ohms.
Corrective Action
Failure of fuel shutoff
valves.
Sheared radial drive shaft,
PTO gear, or AGB input
gearing.
Check that shutoff valves are
energized.
Troubleshoot as required.
Crack gas turbine from pad
on AGB. Check for compressor or HPT rotation using
borescope 2C91 11 I GO I
through compressor or combustor port.
Isolate and replace defective drive component
(WP 032 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page7
31 May 2002
7.
NO START (NO XN2 INDICATION).
Symptom
A.
No XN2 indication
(with oil pressure
indication).
XN2 indication failure.
Corrective Action
Troubleshooting
Possible Cause
Check gas generator speed
sensors. indicator. and electrical leads. Check AGB to verify rotation of crank pad.
Replace gas generator
speed sensors. indicator,
electrical leads. or sensor
wheel as required
(WP 026 00).
CAUTION
Do not operate gas turbine for more than 30 seconds without oil pressure or
damage to gas turbine could result.
B.
No XN2 indication
(without oil pressure
indication).
I.
Starter pressure below
limits.
Check starter supply pressure
(refer to WP 005 I 0 for
limits).
Increase pressure to proper
limit, or replace starter if
pressure is OK
(WP 033 00).
2.
Faulty start selector
switch or open circuit
breaker( s).
Check start selector switch
and circuit breaker(s).
Replace switch and/or
reset circuit breakers.
3.
Starter inoperative.
Check starter.
Replace starter if it does
not rotate, if it cuts out
early, or if drive clutch or
shaft is faulty
(WP 033 00).
4.
Gas generator seizure.
a.
Allow hot gas turbine to
cool for 30 minutes, and
check gas generator rotation with starter or with
ratchet wrench on AGB
crank pad.
Attempt another start after
cooling period and rotation
check.
b.
Check cold gas turbine
rotation with ratchet
wrench on AGB crank
pad.
(I) Replace gas turbine if
wrench cannot rotate
gas turbine.
(2) Replace radial drive
shaft. power takeoff.
or accessory gearbox
(WP 032 00) if
wrench turns but gas
turbine does not
rotate.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
Page 8
7. NO START (NO XN2 INDICATION). (Cont)
Symptom
Possible Cause
c.
5.
8.
Accessory gearbox
failure.
Borescope-inspect
(WP 0 I 0 00) gas turbine
at compressor inlet and
stage 10 port for FOD.
Rotate gas generator using
AGB crank pad.
Remove gas turbine for
repair of FOD if noted.
Replace gearbox
(WP 032 00). Flush scavenge drain system and lube
oil tank as necessary to
remove contaminants.
HOT START (STARTING STALL).
Symptom
Gas turbine stalls during
start. Slow increase in
T4.8 plus XN2 speed
hangup or dropoff.
Possible Cause
I.
2.
9.
Corrective Action
Troubleshooting
Troubleshooting
Variable stator vanes
position is incorrect.
Check variable stator vanes
position while motoring gas
turbine (should be
62-64 degrees).
Fuel pressure irregular.
Check PS3 sensor and line
(customer equipment) for
leaks.
Corrective Action
a.
Check VG feedback
cable for binding and
interference.
b.
Re-rig VG feedback
cable (WP 0 12 00).
Repair or replace defective
component.
GAS TIJRBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE.
Symptom
Possible Cause
Troubleshooting
Corrective Action
I CAUTION I
Do not exceed starter duty cycle.
No or slow acceleration to
idle speed accompanied by
low fuel now and low
T4.8.
I.
Low starter pressure.
Check starter hydraulic oil
pressure. It should be
3,000 psig (20,684 kPa) and
gas turbine should rotate at
5.000 rpm minimum.
Increase pressure to proper
limit.
2.
Starter cutout speed too
low.
Check rpm at which starter
cuts out. It should cut out at
9.500 rpm XN2.
Troubleshoot starter. control valves. and starter
drive clutch.
3.
Fuel contamination.
Check for filter bypass indication.
Blow down fuel system.
Clean or replace all fuel
filters. Reset bypass
indicator.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page9
31 May 2002
9. GAS TIJRBINE DOES NOT REACH IDLE OR SLOW ACCELERATION TO IDLE. (Cont)
Symptom
Possible Cause
4.
Variable stator vanes
position is incorrect.
Troubleshooting
a.
b.
Check variable stator
vanes position while
motoring gas turbine
(should be
62-64 degrees.
Check for excessively
worn VSV linkage or
improper stage-to-stage
rigging.
Corrective Action
(I) Re-rig VG feedback
cable (WP 012 00).
(2) Check for binding and
interferences using
pull check. Pull check
should be I 0 pounds
(4.5 kg) with cable
connected. 4 pounds
( 1.8 kg) with cable
disconnected.
maximum.
Correct rigging of VSV
linkage assembly
(WP 012 00).
5.
P3 tube leakage or defective transducer.
Check for loose. damaged. or
blocked tube, and loss of
electrical signal to control.
Tighten or replace tube.
replace transducer. or
electrical lead.
6.
Compressor/high pressure turbine rotor rubbing excessively.
Bore scope-inspect
(WP 010 00) gas turbine.
Look for rolled material on
blade tip. This indicates
heavy rub.
Replace gas turbine.
7.
Rich/lean shift in acceleration fuel schedule.
Check fuel metering valve
output.
Replace or recalibrate fuel
metering valve.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
10.
Page 10
IDLE SPEED PROBLEMS.
Symptom
Possible Cause
Troubleshooting
Corrective Action
I CAUTION I
Do not operate gas turbine for more than 30 seconds without oil pressure or damage to gas turbine could result.
A. No XN2 indication
(with oil pressure
indication).
Indicator or harness failure.
Check harness and indicator.
Replace faulty component.
B.
No XN2 indication
and no oil pressure
indication.
Loss of signal.
Immediately shut gas turbine
down. Check pump. transducer, indicator, piping and
cabling.
Repair or replace faulty
component.
C.
Idle speed low.
I.
VG control CIT sensor
failure.
Check stator vanes position at
idle.
Replace VG control
assembly (WP 028 00).
2.
P3 tube leakage. blockage. or defective
transducer.
Check for loose. damaged. or
blocked tube.
Tighten or replace tube or
replace transducer.
3.
Faulty speed indication.
a.
Check indicator for
accuracy.
Replace indicator.
b.
Check gas generator
speed sensor(s).
Replace sensor
(WP 026 00).
D. Idle speed high.
E.
Instability.
4.
Fuel metering valve
failure.
Check valve position.
Replace valve.
I.
VG control drive shaft
failure.
a.
XN2 rises to 70 to 85'7<.
depending on accessory
loads.
Replace VG control
assembly (WP 028 00).
b.
XNSD low.
c.
Stator vanes fully closed.
2.
Faulty speed indication.
Check indicator for accuracy.
Recalibrate or replace
indicator.
3.
P3 tube leakage.
Inspect fittings for looseness.
Tighten fittings.
I.
Water in fuel.
2.
Air in fuel system.
Advance power and return to
idle.
Recheck for stability at
idle.
3.
VG control CIT sensor
failure.
Check CIT sensor bulb and
capillary tube for damage.
Replace VG control
assembly (WP 028 00).
Clean fuel system due to
water contamination
(WP 020 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
Page 11
10. IDLE SPEED PROBLEMS. (Cont)
Symptom
F.
Possible Cause
Power turbine rotation
without display
indication.
G. No power turbine
rotation.
Troubleshooting
Corrective Action
4.
VG feedback cable is
binding.
Disconnect feedback cable
and do a pull check. Pull
check should be I 0 pounds
(4.5 kg) when connected,
4 pounds ( 1.8 kg) when
disconnected.
Replace VG feedback
cable (WP 028 00).
5.
Intermittent XN2 output.
Check gas generator speed
sensors and output leads.
Replace defective component (WP 026 00).
I.
Faulty rpm indication.
a.
Visually check power
turbine rotation by
observing ship's gearbox
input shaft.
Verify rotation.
b.
Check indicator, power
turbine speed sensors.
and harnesses.
Replace faulty component
(WP 027 00).
1.
Failure of. or foreign
object lodged in. unit
connected to gas turbine.
Visually inspect ship's gearbox system.
Repair or replace faulty
component.
2.
Power turbine blade/
shroud or interstage seal
seizure.
Allow gas turbine to cool for
2 hours and then attempt to
rotate.
Repair or replace gas
turbine.
I CAUTION I
Do not exceed IDLE power or damage to gas turbine may occur.
3.
Wear-in of new shrouds
and seals on initial
startup. (Probable cause
if turbine is free to rotate
when cold.
Operate gas turbine at idle
speed for 5 minutes. Shut gas
turbine down if power turbine
does not rotate.
Allow gas turbine to cool
down until power turbine
is free. and repeat start.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
11.
Page 12
ABNORMAL ACCELERATION TO MAX POWER.
Symptom
A.
B.
c.
No acceleration.
Slow acceleration
with low T4.8.
Slow acceleration
with high T4.8.
D. Compressor stall.
Possible Cause
Troubleshooting
Corrective Action
I.
Fuel metering valve
failure.
Check valve position.
Replace fuel metering
valve.
2.
Compressor discharge
pressure system leak.
blockage. or transducer
failure.
Check for loose, damaged. or
blocked Iincs.
Tighten or replace lines, or
replace PS3 transducer.
I.
Low fuel inlet pressure.
Check inlet pressure.
Troubleshoot per
paragraph 14 (Flameout).
2.
Fuel filter blocked.
Bypass indication.
Service fuel filter
(WP 020 00).
3.
Compressor discharge
pressure system leak.
blockage, or transducer
failure.
Check for loose. damaged. or
blocked lines. and PS3
output.
Tighten or replace lines, or
replace sensor.
I.
Foreign object damage.
Borescope-inspect gas turbine
(WP 010 00).
Replace gas turbine if
FOD exceeds limits.
2.
Variable stator vanes
schedule failure.
Check variable stator vanes
schedule (WP 012 00).
Check for binding VSV actuator or linkage assembly.
a.
Re-rig VG feedback
cable (WP 012 00).
b.
Replace VG control
assembly
(WP 028 00).
c.
Repair linkage assembly (WP 029 00).
3.
Dirty compressor.
Borescope-inspect gas turbine
(WP 010 00) or check gas
generator pressure ratio.
Water-wash compressor
(WP 017 00).
I.
VG feedback cable is
binding.
Disconnect VG feedback
cable and do a pull check.
Pull check should be
I0 pounds (4.5 kg) when connected. 4 pounds ( 1.8 kg)
when disconnected.
Replace VG feedback
cable (WP 028 00).
2.
Variable stator vanes
schedule failure.
Check variable stator vanes
schedule (WP 012 00).
Re-rig VG feedback cable
(WP 012 00).
3.
VG control CIT sensor
failure.
Check sensor.
Clean sensor (WP 009 00)
or replace VG control
assembly (WP 028 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 13
31 May 2002
11. ABNORMAL ACCELERATION TO MAX POWER. (Cont)
Symptom
E.
XN2 or T4.8
overshoot at base
load.
Possible Cause
Troubleshooting
Corrective Action
4.
Stator vane lever arm
broken or disconnected.
Check to see that all vane
lever arms are engaged in
holes of actuator rings.
If any lever arms are broken or disconnected. contact GE for assistance.
5.
Foreign object damage.
Borescope-inspect gas turbine
(WP 010 00).
Replace gas turbine if
FOD exceeds limits.
6.
VG control assembly
defective.
Inspect VG control assembly
(WP 028 00).
Replace VG control
assembly (WP 028 00).
I.
Variable stator vanes are
not fully open.
XN2 reaches 17.600 rpm but
T4.8 and XNSD remain low.
a.
Check for free travel
of stator system.
b.
Check rigging of VG
feedback cable
(WP 012 00).
c.
If problem persists.
replace VG control
assembly
(WP 028 00).
2.
12.
Faulty XN2/T4.8
indications.
Check indicator systems.
Repair or recalibrate
indicators.
ABNORMAL DECELERATION FROM HIGH POWER.
Symptom
Possible Cause
A. Flameout or low XN2.
Leaking P3 tube to PS3 sensor connection.
B.
I.
2.
Compressor stall.
Troubleshooting
Corrective Action
Slow starts and slow acceleration with low T4.8.
Repair or replace P3 tube
or PS3 sensor.
VG feedback cable is
binding.
Disconnect both ends of VG
feedback cable and check for
free travel. Pull check should
be 4 pounds ( 1.8 kg)
maximum.
Replace VG feedback
cable (WP 028 00).
VG control feedback
lever defective.
Check for free travel of lever.
Replace VG control.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 14
31 May 2002
13.
HIGH POWER (STEADY-STATE) PROBLEMS.
Possible Cause
Symptom
A. Low XNSD in AUTO
mode.
B.
I.
Excessive output shaft
torque (T4.8 limiting).
Corrective Action
Troubleshooting
a.
Check torque.
Reduce torque.
b.
Check for possible cornpressor discharge air leak
at capped stage I0 or
stage 14 bleed ports. or
leak in sump pressurization air lines.
Eliminate leakage.
2.
Dirty compressor.
Check performance (gas turbine pressure ratio) or borescope-inspect (WP 0 I0 00)
compressor.
Water-wash gas turbine
(WP 017 00).
3.
Low fuel flow.
a.
Check P3 tube and
transducer.
Replace tube or
transducer.
b.
Check VG schedule
(WP 012 00).
Replace VG control
assembly (WP 028 00).
RPM fluctuation or
T4.8 fluctuation in
AUTO control mode.
NOTE
Fluctuation of a single instrument, without similar fluctuation of related instruments, indicates instrument malfunction.
I.
Faulty XN2/Wfff4.8
indicators.
Check indicators for
accuracy.
Replace faulty indicator.
2.
VG feedback cable is
binding.
Disconnect VG feedback
cable and check for free
travel.
Replace VG feedback
cable (WP 028 00).
3.
Fuel supply system
defective.
a.
Check fuel header
pressure.
Correct as required.
b.
Check emergency shutoff
valve for full open
position.
Reposition or replace
valve.
4.
Clogged fuel filter.
Check bypass indicator
button.
Service fuel filter
(WP 02000).
5.
Worn or unstable fuel
metering valve.
Check fuel metering valve
operation.
Replace fuel metering
valve.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 15
31 May 2002
13. HIGH POWER (STEADY-STATE) PROBLEMS. (Cont)
Symptom
c.
Higher or lower T4.8
than previous reading
at max.
Possible Cause
Stall during steadystate operation.
Corrective Action
6.
Oxidized electrical
connectors.
Check T4.8 harness electrical
connectors for contamination/
oxidation.
Clean electrical connectors
or replace harness.
7.
Compressor discharge
pressure system leak.
Check for loose or damaged
compressor bleed hlankoff
plates or leakage in sump
pressurization lines.
Correct as required.
I.
If all other readings are
the same as those previously taken at rated load:
2.
D.
Troubleshooting
a.
Faulty indicator.
Check T4.8 input and indicator for accuracy.
Replace indicator.
h.
Faulty T4.8 harness.
Measure harness pin-to-pin
and pin-to-ground resistance.
Replace faulty harness.
If all other readings
changed with T4.8:
a.
Dirty compressor
blades.
Borescope-inspect compressor (WP 0 I 0 00).
Water-wash gas turbine
(WP 017 00).
h.
CIT sensor failure.
Check CIT sensor.
Replace CIT sensor
(WP 009 00).
c.
Foreign object
damage.
Borescope-inspect gas turbine
(WP 010 00).
Replace gas turbine if
FOD exceeds limits.
d.
VG control
assembly is
defective.
Inspect VG control assembly
(WP 028 00).
Replace VG control
assembly (WP 028 00).
I.
Disengaged or broken
vane lever arms.
Check that all vane lever arms
are properly engaged in actuator rings.
If any lever arms are hroken or disconnected. contact GE for assistance.
2.
Inlet screen restricted hy:
(I) Melt ice with portable
heater. Borescopeinspect (WP 0 I 0 00) gas
turbine for FOD caused
hy ice formation on
IGV's.
Replace gas turbine if
FOD exceeds limits.
a.
Ice.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 16
31 May 2002
13. HIGH POWER (STEADY-STATE) PROBLEMS. (Cont)
Symptom
b.
14.
Troubleshooting
Possible Cause
Foreign objects
(except ice).
Corrective Action
(2) Remove objects restricting inlet screen. Borescope gas turbine if any
deterioration in screen
integrity is found or there
is possibility that objects
passed through screen
into compressor.
Replace gas turbine if
FOD exceeds limits.
3.
Incorrect variable stator
vanes position.
Check variable stator vanes
schedule (WP 012 00).
Re-rig VG feedback cable
(WP 012 00).
4.
Foreign object damage.
Borescope-inspect gas turbine
(WP 010 00).
Replace gas turbine if
FOD exceeds limits.
FLAMEOUT.
Possible Cause
Symptom
Low or no fuel manifold
pressure indication.
Troubleshooting
Corrective Action
Check fuel supply pressure to
gas turbine fuel pump
(5 to 55 psig (34-379 kPa)).
Correct per ship's manual.
I.
Fuel supply system
defective.
2.
Fuel contamination.
3.
Incorrect variable stator
vanes position if flameout happened during
compressor stall.
Check variable stator vanes
schedule (WP 012 00).
P3 sensing line transducer is leaking.
a.
Inspect line for leaks or
looseness.
Tighten or replace line.
b.
Check operation and calibration of transducer.
Recalibrate or replace
transducer.
4.
Service fuel system
(WP 020 00).
a.
Re-rig VG feedback
cable (WP 012 00).
b.
Replace VG control
assembly
(WP 028 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 17
31 May 2002
15.
LUBRICATION SYSTEM PROBLEMS.
Symptom
Possible Cause
Troubleshooting
Corrective Action
A.
Oil tank is
contaminated.
Maintenance error/abnormal
SOAP sample.
If gas turbine operated for
200 hours or more with
MIL-L-23699 oil containing
more than 57t mineral oiL
remove C-sump cover and
inspect for excessive coking
and deposits.
Service lube system
(WP 019 00).
B.
No oil pressure.
I.
Sheared pump shaft.
Check for XN2 indication
while motoring gas turbine.
Verify lube supply to pump.
Replace pump
(WP 031 00) if there is no
oil pressure with an XN2
indication and normal oil
supply to pump.
2.
Low oil level in tank.
Check for source of abnormal
oil loss such as a loose connection. a crack in line or in a
tank weld. a failed pump seaL
an open SOAP sampling
cock, or a loose drain fitting.
Check for oil carryover to gas
turbine through tank vent line
to compressor front frame.
Correct the problem.
3.
Faulty oil pressure
indication.
Check indicating system for
faulty circuits.
Replace faulty component.
4.
Faulty transmitter or
pressure line.
Check transmitter for open
circuit or for a loose or broken pressure line.
Replace faulty component.
5.
Obstruction in oil supply
hose-to-pump.
a.
Disconnect supply hose
at pump, and check for
presence of oil.
Correct the problem.
b.
Check oil supply hose for
deterioration (collapsed).
Replace oil supply hose
(WP 031 00).
c.
Check for obstruction in
pump inlet.
Remove obstruction from
pump and clean oil tank.
d.
Check for improperly
connected lines or
reversed check valve.
Correct the problem.
6.
Inlet screen in tank (for
pump supply line)
obstructed.
Remove inlet screen and
check for obstructions.
Remove obstruction and
clean oil screen and tank.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00610
Page 18
31 May 2002
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Possible Cause
Symptom
C.
Troubleshooting
Corrective Action
Low oil pressure.
NOTE
A decrease of I 0 psig (69 kPa) from the normal pressure is cause for investigation. Do not operate gas turbine if pressure is more than 15 psi (I 03 kPa) below
minimum.
I.
With fluctuation.
a.
Low oil level in tank.
Check oil level.
Refill oil tank to correct
level.
b.
External oil leak.
Inspect all external lines and
components for leaks.
Replace leaking component. Torque loose fittings (WP 031 00).
c.
Faulty oil pressure
indication.
Check indicating system for
accuracy.
Replace faulty component.
d.
Failure of pressure relief
valve in lube and scavenge pump.
e.
Obstructed or collapsed
oil supply hose-to-pump.
Replace lube and scavenge
pump (WP 031 00).
(I) Disconnect supply hose
at pump and check for
flow.
(2) Check oil-in hose for
deterioration.
(3) Check for obstruction in
pump inlet.
2.
Without fluctuation.
Replace supply hose
(WP 031 00).
Replace oil-in hose
(WP 031 00).
Remove obstruction from
pump.
a.
External oil leak.
Inspect for leaks.
Repair leak.
b.
Internal gas turbine leak
(possible damaged oil
seals).
Check for high oil
consumption.
Repair or replace gas
turbine.
c.
Faulty pressure transmitter or cable.
Install another transmitter to
verify original pressure readings. Check transmitter for
short circuit.
Replace transmitter or
cable.
d.
Oil/fuel contamination.
Check oil sample for fuel
dilution. Pressure leak-check
oil tank if fuel is found in oil.
(I ) Repair source of fuel
entry into oil.
(2) Service lube system
(WP 019 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
Page 19
15. LUBRICATION SYSTEM PROBLEMS. (Con!)
Symptom
D.
Possible Cause
Troubleshooting
Corrective Action
High oil pressure.
CAUTION
Do not operate gas turbine if oil pressure exceeds 30 psig (207 kPa) above normal pressure, after gas turbine reaches stabilized temperature: otherwise, damage
to gas turbine may occur.
NOTE
•
•
An increase in oil pressure of I 0 psig (69 kPa) over normal pressure is cause for
investigation. Do not replace the oil pump because it cannot be the cause of
high oil pressure.
Oil pressure during initial start (cold oil) should return to normal after
5 minutes at IDLE speed, but may take considerably longer under severe freezing conditions. Higher power settings are required for more rapid warm-up.
I.
Low oil temperature after
warm-up.
2.
Faulty oil pressure
indication.
Check indicating system for
accuracy.
Replace faulty component.
3.
Plugged oil filter.
Remove and inspect oil filter
(WP 019 00).
Service oil filter
(WP 019 00).
4.
Check valve. in oil filter,
is stuck.
5.
Blocked or kinked oil
tubes.
Check tubes for kinks or
blockage (WP 031 00).
Clean or replace faulty
tube (WP 031 00).
6.
Clogged oil tubes and oil
jets. (This is often indicated by tendency of
pressure to creep up.)
If oil filter was plugged but
the replacement oil filter did
not reduce pressure to within
limits. remove and inspect
chip detectors (WP 013 00)
and record location where
metal chips and sludge were
found.
Replace gas turbine.
7.
Restriction or blockage
in oil tank vent line to
gas turbine.
Check for restriction.
Clean or replace faulty
component.
Operate gas turbine to
allow pressure to decrease
after warm-up.
Replace oil filter
(WP 019 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
Page 20
IS. LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
E.
Possible Cause
Troubleshooting
Corrective Action
Fluctuating oil
pressure (greater than
5 psi (34 kPa)).
NOTE
Fluctuating oil pressure during transient conditions is considered normal; however. these fluctuations should stop I minute after returning to steady-state
conditions.
F.
Overfull oil tank.
I.
Low oil level in tank.
Check oil level.
Refill oil tank to correct
level.
2.
Oil/water
contamination.
Check oil sample for milky
appearance or for dilution
with water. Pressure-check
oil tank if water is found in
oil.
a.
Repair source of water
entry into tank.
b.
Service lube system
(WP 019 00).
3.
Plugged oil filter.
Remove and inspect oil filter
(WP 019 00).
Service oil filter
(WP 019 00).
4.
Faulty oil pressure
transmitter.
Check transmitter for accuracy.
Replace transmitter.
5.
Blocked or defective Iube
and scavenge pump inlet
hose.
a.
Disconnect inlet hose
and check for blockage
or damage.
Clean or replace hose
(WP 031 00).
b.
Inspect oil tank for
blocked screen.
Clean the tank and screen.
Replace Iube and scavenge
pump (WP 031 00).
6.
Failure of pressure relief
valve in lube and scavenge pump.
7.
Defective oil tank vent.
Remove cover and inspect
deaerator for cracks.
Repair or replace oil tank.
8.
Defective oil pump-toAGB drive pad seal.
Check seal for oil leakage or
oil wetting.
Replace pump
(WP031 00).
I.
Fuel in tank.
Check oil sample
(WP 015 00) for fuel.
a.
Determine and repair
source of fuel entry.
b.
Service Iube system
(WP 019 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 21
31 May 2002
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Symptom
Possible Cause
2.
Corrective Action
Troubleshooting
Added too much oil.
Incorrect servicing
procedure.
Drain excess oil.
G. High oil temperature
(oil appears as though
it has been
overheated).
NOTE
Indication of overheated oil is apparent by extremely dark oil in oil tank, by a
pungent burned odor, by sludge and varnish deposits on oil filter. or sludge on
chip detectors.
I.
Low oil level in tank.
Check oil level.
Refill oil tank to correct
level.
2.
Low oil tlow in B-and/or
C-sump. resulting in high
scavenge temperature.
a.
Replace B- and C-sump
chip detectors
(WP 013 00) and thermocouple harness
(WP 025 00).
Record the sump area that
exceeded the limits. and
replace gas turbine.
b.
Operate gas turbine and
record B- and C-sump
scavenge oil temperature
and temperature at oil
cooler output. Max
allowable temperature at
air/oil cooler oil output is
350°F ( I77°C).
c.
Subtract the temperature
at the air/oil cooler from
each of the B- and Csump scavenge temperatures. The resulting differential temperature
should be below the following limits:
B-sump: 160°F (71 °C)
C-sump: 130°F (54 °C)
d.
H. Fluctuating oil
temperature.
Faulty oil temperature indicating system.
Check for high or low oil
pressure.
Check indicating system for
accuracy.
Replace faulty component.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
Page 22
15. LUBRICATION SYSTEM PROBLEMS. (Cont)
Possible Cause
Symptom
I.
Troubleshooting
Corrective Action
High oil consumption.
CAUTION
Do not operate gas turbine with Jluctuating or below limits oil pressure. A sudden increase in oil consumption or a gradual increase over a period of time indicates deterioration of the oil system and is cause for investigation.
I.
Records in error.
2.
Oil leaks in:
Exhaust fire and
smoke.
Correct records.
a.
External hoses and
tubes.
Inspect hoses. tubes. and fittings for leaks.
Replace hose. tube, or
fitting (WPm I 00).
b.
Accessory gearbox.
I.
Check each gearbox pad
Jlange for leakage:
5 cc/minute normal leak-.
age during operation.
Replace defective parts.
2.
Check packings and seals
for damage.
Replace defective parts.
c.
J.
Verify records.
Oil pump.
Check oil pump seal drain:
5 cc/minute normal leakage
during operation.
Replace oil pump
(WPm! 00).
3.
Plugged A-sump seal
drain tube (oil wetted
areas in coupling guard).
Attach a tube to A-sump
drain tube and blow through
gently. Tube must have no
restrictions.
Clean (WPm I 00) drain
tube and orifice (from
6 o'clock front frame pad).
4.
Plugged seal pressure
tube to C-sump.
Attach a tube to C-sump tube
and blow through gently.
Tube must have no restrictions.
Clean (WPm I 00) tube
(from pressure regulating
valve to 12 o'clock strut
on exhaust frame).
5.
Internal gas turbine damage.
Check oil filters. chip detectors, and SOAP reports.
Replace gas turbine.
Fire or excessive smoke
observed in tailpipe.
Replace damaged C-sump
scavenge hose
(WPmi 00).
Restricted or damaged
C-sump scavenge hose.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
00610
31 May 2002
16.
Page 23
HIGH VIBRATIONS.
Symptom
Possible Cause
Troubleshooting
Corrective Action
NOTE
•
•
A.
B.
Occasionally it may he noted that vibrations increase as much
mils after a
shutdown of I to 2 hours. The most probable cause is a temporary thermal
rotor how due to uneven cooling of the power turbine or gas generator rotors. If
the shutdown is brief (less than I 0 minutes) or long (more than 6 hours). thermal rotor bow cannot occur because the rotors cool either very little or to a uniform temperature.
A thermal rotor how can be identified by noting that the increased vibration levels gradually decay hack to previous levels during approximately 10 minutes of
gas turbine operation. As long as vibrations are decreasing with time, gas turbine operation may he continued even if some limits are temporarily exceeded.
Gas generator rotor
vibration.
Power turbine rotor
vibration.
I.
Faulty vibration indicating system.
Check all connections and
pickups for looseness. Check
leads for chafing. Check
indicators for accuracy.
Replace faulty component.
2.
Loose gas turbine
mounts.
Check gas turbine mounts for
security and alignment.
Realign and tighten
mounts.
3.
Foreign object damage.
Borescope-inspect gas turbine
(WP 01000).
Replace gas turbine.
4.
Defective hearings.
a.
Refer to paragraph 15.
items B and C.
h.
Check oil filter and chip
detectors for debris.
Replace gas turbine.
c.
Check SOAP reports for
signs of impending hearing failure.
Replace gas turbine.
Water-wash gas turbine
(WP 017 00).
5.
Dirty compressor.
I.
Faulty vibration indicating system.
Check all connections and
pickups for looseness. Check
leads for chafing. Check
indicators for accuracy.
Replace faulty component.
2.
Loose gas turbine
mounts.
Check gas turbine mounts for
security and alignment.
Realign and tighten
mounts.
3.
Foreign object damage.
Borescope-inspect gas turbine
(WP 010 00).
Replace gas turbine.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
Page 24
31 May 2002
17.
POST-SHUTDOWN FIRE.
Symptom
After shutdown, T4.8 indicates 52rF (275°C) or
higher.
18.
Possible Cause
B.
Corrective Action
I.
High ambient temperatures.
With ambient temperature at
I 00°F (38°C) or above, a
T4.8 of 527°F (275°C) or
slightly higher can be normal.
Motor gas turbine with
starter. ignition otf. until
T4.8 indicates 392°F
(200°C) or less.
2.
Shutoff valves open.
Motor gas turbine and check
for fuel flow indication and
vapors. If present. check
shutoff valves.
Replace shutoff valves.
OVERSPEED/OVERTEMPERATURE.
Possible Cause
Symptom
A.
Troubleshooting
XN2 or T4.8
overshoot at max.
Different XN2 than
previous readings
under same operating
conditions.
I.
Variable stator vanes are
not fully open. XN2
reaches 17.600 rpm but
T4.8 and XNSD remain
low.
Troubleshooting
a.
Check for free travel of
variable stator system.
b.
Check rigging of VG
feedback cable
(WPOI200).
Corrective Action
If problem persists,
replace VG control assembly (WP 028 00).
2.
Faulty XN2/T4.8
indications.
Check indicator systems.
Repair or recalibrate
indicators.
3.
Thermocouple harness
(open. short circuit).
Inspect thermocouple harness (WP 025 00).
Replace thermocouple harness (WP 025 00).
4.
Fuel metering valve
failure.
Check for worn valve.
Replace fuel metering
valve.
I.
If all other readings are
the same as those previously taken, indicator
may be faulty.
Check indicator output.
Replace faulty component.
2.
If XN2 and XNSD are
both low:
a.
Dirty compressor
rotor.
Borescope-inspect gas turbine
(WP 010 00).
Water-wash gas turbine
(WP 017 00).
b.
Foreign object
damage.
Borescope-inspect gas turbine
(WPOIOOO).
Replace gas turbine.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
00610
GEK 99441
31 May 2002
Page 25/26
18. OVERSPEED/OVERTEMPERATURE. (Cont)
Symptom
C.
Higher T4.8 than
previous reading at
I 00% power under
same operating
conditions.
Possible Cause
Troubleshooting
Corrective Action
c.
Compressor air leak.
Check sump pressurizing and
balance piston lines and port
blankotfs.
Eliminate leakage.
d.
Excessive power
extraction (AGB ).
Check for binding or abnormal torque on AGB mounted
components or for failure
within AGB.
Replace defective components (WP 032 00).
3.
If XN2 increases and
XNSD decreases, variable vanes are misrigged
(closed).
Check variable vane schedule (WP 012 00).
Re-rig VG feedback cable
(WP 012 00).
4.
If XN2 and XNSD
increase. thermocouple
harness has failed.
Inspect thermocouple harness (WP 025 00).
Replace thermocouple harness (WP 025 00).
I.
If all other readings are
the same as those previously taken, indicator
may be faulty.
Check indicator output.
Replace faulty indicator.
2.
If all other readings
changed with T4.8:
a.
Variable stator vanes
off schedule.
Check VG feedback cable for
looseness (WP 012 00).
Adjust VG feedback cable
(WP 012 00).
h.
CIT sensor failure.
Check CIT sensor.
Clean sensor (WP 009 00)
or replace VG control
assembly (WP 028 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
007 00
GEK 99441
Page 1 of 36
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
GENERAL MAINTENANCE PRACTICES AND INSPECTION INSTRUCTIONS
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G01 /-G03/-G04/
-G05/-G06
L32112G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Consumable Materials ................................................................
General Inspection Instructions .........................................................
Crack Description ................................................................
Definitions of Inspection Terms ......................................................
Evaluation of Gas Turbine Part Serviceability Using the Borescope ..........................
Extent and Methods of Inspection ....................................................
Organization oflnspection Data ......................................................
Shop Practices ...................................................................
General Maintenance Practices .........................................................
Hand Tools ........................................................................
Introduction ........................................................................
Maintenance Techniques ..............................................................
Bearing Handling Practices .........................................................
Bearing Installation Practices ........................................................
Cotter Pin Practices ...............................................................
Lock-Wiring Practices .............................................................
Lubricants .......................................................................
Offset Extension (Crowfoot) Wrench ..................................................
Offset Extension (Crowfoot) Wrench Computations ......................................
Positioning and Non-Positioning Type Fittings Installation Practices .........................
Preformed Packings Installation Practices ..............................................
Spectrometric Oil Analysis Program (SOAP) ...........................................
Torque-Tightening Practices ........................................................
Torque Wrench Sizes ..............................................................
Special Inspection Requirements .......................................................
Standard Maintenance Practices ........................................................
Alodine 1200 Touchup .............................................................
Blending Procedures ...............................................................
Cold-Working ....................................................................
Vapor Degreasing .................................................................
White-Light Inspection ............................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
2
21
28
21
21
21
27
21
3
4
I
10
10
11
15
12
19
21
21
15
18
19
19
20
33
28
31
28
28
32
30
2
1.
INTRODUCTION. This work package provides instructions for general maintenance practices and techniques. and
inspection methods for the LM500 gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00700
GEK 99441
31 May 2002
2.
Page 2
SUPPORT EQUIPMENT.
Support Equipment
Nomenclature
Part No.
White Light, 150-Watt
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Acid, Nitric (0-N-350)
Local Purchase
Acid, Phosphoric (0-0-670)
Local Purchase
Alcohol, Isopropyl (TT-I-735)
Local Purchase
Alodine No. 1200
Parker & Amchem
32102 Stephenson Hwy.
Madison Heights, MI 48071
USA
Bags, Polyethylene
Local Purchase
Bits, Grinding
Local Purchase
Brush, Soft-Bristle
Local Purchase
Brush, Rotary
Local Purchase
Brush, Stainless Steel Wire
Local Purchase
Burr. Carbide Rotary
Local Purchase
Caps. Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo. NY 14207
USA
Cloth. Abrasive
( 120-180 Grit)
( 150-240 Grit)
(250-300 Grit)
(400-500 Grit)
Local Purchase
Cloth. Crocus
(500-600 Grade)
Local Purchase
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00700
GEK 99441
Page3
31 May 2002
Consumable Materials (Cont)
Description
Manufacturer
Cloth, Emery
( 150-600 Grit)
Local Purchase
Cloth, Lint-Free
Local Purchase
Compound, Antiseize
(Bray cote 655)
Bray Oil Co. Inc.
2698 White Rd.
lrvine. CA 92714
USA
File, Rotary
Local Purchase
Gloves. Rubber or Polyethylene
Local Purchase
Marker. Blue Dykem (M-1)
Dykem Co.
8501 Delport Dr.
St. Louis, MO 63114
USA
Material, Water- Vapor-proof Barrier
(MIL-B-131)
Local Purchase
Oil, Lubricating
(MIL-L-7808 or MIL-L-23699)
Local Purchase
Petrolatum
Local Purchase
Plugs. Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo. NY 14207
USA
Solvent. Tetrachloroethylene
(Perchloroethylene) (0-T-236)
Local Purchase
Solvent. Trichloroethane
(0-T-620)
Local Purchase
Solvent. Trichlorotritluoroethane
(MIL-C-81302)
Local Purchase
4. GENERAL MAINTENANCE PRACTICES. Maintenance personnel must familiarize themselves with the following
general practices before attempting to do any maintenance on the gas turbine or its components.
a.
The purpose of this work package is to guide and enhance the judgment and experience of qualified personnel.
b.
Record on the appropriate forms the critical measurements taken during disassembly as follows:
(I)
Specify both the name of the part that is measured and the area of measurement on the part.
(2)
During disassembly. inspect all parts for serviceability.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00700
31 May 2002
Page4
(3) Look for indications of work performed incorrectly during previous maintenance or overhaul. Report any
such indications in accordance with current practices.
c.
Discard unserviceable parts in accordance with current regulations. Discard all preformed packings, gaskets,
and tab washers that are removed during disassembly.
CAUTION
•
•
•
•
Do not use cadmium-plated tools/fixtures for maintenance or repair of parts. Cadmium-plated tools/fixtures will embrittle many metals, including titanium,
if they are exposed to temperatures of 500°F (260°C)
and above.
Do not use brass or lead tools when installing or disassembling hot section parts. Brass and lead contaminants can ultimately lead to part failure.
Use of tools which appear physically similar to those
authorized can result in gas turbine damage. Where
special tools are identified. use of these tools by tool
number is the only correct practice to follow unless an
alternate tool is given for the task.
To prevent possible stress corrosion, do not use adhesive paper or tape containing chlorine compounds on
titanium parts.
d. The special tools identified in this manual are designed specifically for use on this gas turbine. Avoid the use of
makeshift tools. Refer to table I for a list of recommended hand tools.
e.
Before using tools, be sure that the tools are clean and free from nicks, dents, or burrs that could damage gas turbine parts. Lubricate tool threads and sliding surfaces.
f.
Do not use hammers with metal heads on any part of the gas turbine. Use hammers with plastic, nylon, or rawhide heads. Do not use screwdrivers or sharp metal rods to separate gas turbine parts. If parts are bound or seized, use wooden
wedges to separate them.
g.
Where lock wire is used, remove it before dismantling parts.
h.
Most locknuts are elliptical in shape by design intent: do not discard as unserviceable for this reason.
i.
Always use two wrenches when disconnecting or tightening hoses and tubes: use one wrench to hold the fitting
and another wrench to loosen or tighten the coupling nut.
J.
Before disconnecting tubes and hoses, remove the locknuts and bolts from the cushioned clamps. This prevents
damage to the fittings. If the same tubes and hoses are to be reinstalled, installation will be easier if the clamps are not
removed from tubes and hoses.
k. When disconnecting tubes and flexible hoses, be careful to prevent damage and twisting action on the tubes and
flexible hoses. As tubes and flexible hoses are disconnected, cap or cover openings to prevent entrance of foreign material.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
007 00
GEK 99441
PageS
31 May 2002
CAUTION
•
•
•
Do not use pliers on electrical connectors. Ferrules
should be hand-tightened; otherwise. connectors will
be damaged.
Do not allow water, fuel, or oil to contact exposed
electrical connectors. Moisture can cause short
circuits.
Do not cover electrical connectors with plastic bags or
aluminum foil. Moisture can accumulate due to water
vapor condensation. Aluminum foil particles and
moisture could cause shorts circuits.
TABLE 1.
RECOMMENDED HAND TOOLS
Nomenclature/Size
Quantity
Adapter. Socket, Square. Drive
1/4 inch Female- 3/8 inch Male
3/8 inch Female - I /4 inch Male
Adapter. Torque Wrench, 1/4 inch Square. Drive
1/4 inch Opening (2 inch offset box end)
5116 inch Opening (2 inch offset box end)
Adapter. Torque Wrench. 3/8 inch Square. Drive
3/8 inch Opening (2 inch offset box end)
7/16 inch Opening (2 inch offset box end)
Crowfoot Attachment. Open End, 3/8 inch Square. Drive
9/16 inch Opening
5/8 inch Opening
I 1116 inch Opening
3/4 inch Opening
13/16 inch Opening
7/8 inch Opening
I inch Opening
1-1/16 inch Opening
1-118 inch Opening
Extension. Socket Wrench, 1/4 inch Square. Drive
2 inch Nominal Length
6 inch Nominal Length
Extension, Socket Wrench, 3/8 inch Square. Drive
3 inch Nominal Length
6 inch Nominal Length
8 inch Nominal Length
12 inch Nominal Length
Extractor. Cotter Pin
Finger. Mechanical. Flexible
Flashlight
Gage. Thickness 0.0015-0.035 inch (0.04-0.90 mm)
Hammer. Plastic. 4 ounces ( 113 grams)
Hammer. Ball Peen. 8 ounces (227 grams)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 6
TABLE 1.
RECOMMENDED HAND TOOLS (Cant)
Nomenclature/Size
Quantity
Handle, Hinge
1/4 inch Square Drive
3/8 inch Square Drive
Handle, Ratchet. Reversible
1/4 inch Square Drive
3/8 inch Square Drive
3/4 inch Square Drive
Handle. Speed
1/4 inch Square Drive
3/8 inch Square Drive
Mirror, Inspection
1-1/8 inch (28.6 mm) Diameter, 6-3/4 inch (172 mm) long
I inch x 2 inches. (25 x 51 mm). 8-112 inches (216 mm) long
Pliers
Conduit
Diagonal
Duckbill
Electrical Connector
Long Nose
Snap Ring
Vise Grip
Wire Twister
Punch Drive Pin. Straight
I /8 inch Point
3116 inch Point
1/4 inch Point
Punch, Drive Pin. Tapered, 3116 inch point Diameter
Retrieving Tool, Magnetic 17-27 inches (43-69 cm) Length
Rule, SteeL 6 inch (15 cm)
Screwdriver Set. Common
Screwdriver Set. Phillips
Socket, I /4 inch Square Drive, Flexible, 12 Lobes
1/4 inch Size Opening
5/16 inch Size Opening
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
Socket, 1/4 inch Square Drive, Long, Thin WaiL 12 Lobes
7/32 inch Size Opening
1/4 inch Size Opening
5116 inch Size Opening
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 7
TABLE 1.
RECOMMENDED HAND TOOLS (Cant)
Nomenclature/Size
Quantity
Socket. I /4 inch Square Drive. Regular Length. 12 Lobes
7/32 inch Size Opening
1/4 inch Size Opening
5116 inch Size Opening
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
Socket. I /4 inch Square Drive, Short. Thin Wall. 12 Lobes
7/32 inch Size Opening
1/4 inch Size Opening
5116 inch Size Opening
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
Socket, 3/8 inch Square Drive. Deep Length. 12 Lobes
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
9/16 inch Size Opening
5/8 inch Size Opening
Socket. 3/8 inch Square Drive, Flexible. 12 Lobes
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
9/16 inch Size Opening
5/8 inch Size Opening
Socket, 3/8 inch Square Drive, Regular Length. 12 Lobes
3/8 inch Size Opening
7116 inch Size Opening
1/2 inch Size Opening
9/16 inch Size Opening
5/8 inch Size Opening
Universal Joint
1/4 inch Square Drive
3/8 inch Square Drive
Wrench. Box End, 12 Lobes
7/32 inch x 1/4 inch Openings
1/4 inch x 5/16 inch Openings
5116 inch x 5/8 inch Openings
7116 inch x 1/2 inch Openings
Wrench. Box End. Ratcheting. 12 Point
1/4 inch Opening
5116 inch Opening
3/8 inch Opening
7/16 inch Opening
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 8
TABLE 1.
RECOMMENDED HAND TOOLS (Cant)
Nomenclature/Size
Quantity
Wrench. Combination. Box (12 Lobes) and Open End
1/4 inch Opening
5116 inch Opening
3/8 inch Opening
7116 inch Opening
1/2 inch Opening
9/16 inch Opening
5/8 inch Opening
11 I 16 inch Opening
3/4 inch Opening
13/16 inch Opening
7/8 inch Opening
I inch Opening
I.
Use extreme care when disconnecting electrical leads. Do the following:
(I )
Remove and discard preformed packings from electrical connectors.
(2)
Cap all ends to prevent entrance of dirt. oil. and moisture using only recommended protective caps or
plugs.
m. To aid in assembly, mark bolts with the number of the flange bolt circle hole they were removed from. Observe
the following:
(I)
Do not mix bolts and locknuts from one part of the gas turbine with those from another.
(2) During assembly, be careful not to drop nuts. washers. pieces of lock wire, or other objects into the subassembly. If an object is dropped. do not proceed further until it is removed.
n.
Do not place tools on any part of the gas turbine during assembly. Return each tool to its proper place immediately after use.
When installing body-bound bolts. align the bolts properly and drive them straight through with a plastic hamo.
mer. Do not rotate these bolts: rotation of bolts tends to loosen them. impairing alignment.
p.
Use care when assembling bolts to shanktype locknuts. Align the bolts and engage the first few threads manually to avoid a shock that could dislodge the locknut from its seat.
q.
All used locknuts must be tried for self-locking capabilities before being used. Do the following:
(I)
Manually thread used locknut onto bolt or stud.
(2)
Any lock nut is serviceable if end of bolt or stud does not extend beyond end of locknut.
r.
Be sure to use the correct bolt and nut at assembly. The bolt. when assembled and properly torqued. should protrude two to three threads beyond the nut.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
00700
GEK 99441
Page9
31 May 2002
Isopropyl Alcohol, TT-1-735
11
s.
Condensation can form on all parts that have been chilled with dry ice (solidi tied carbon dioxide) to facilitate
assembly. Remove this condensation by wiping the part with a lint-free cloth saturated with isopropyl alcohol and then with a
dry lint-free cloth.
t.
Lift all heavy parts with the proper lifting device to prevent damage to the part or injury to personnel.
u.
Always use thermally insulated gloves when handling hot or chilled gas turbine parts.
v.
Do not use excessive force to assemble mating parts. If excessive force appears necessary. inspect mating surfaces for burrs or metal pickup. Remove any such defects and repair or replace defective parts.
w. Carbon seals must be assembled in a clean work area. Prior to assembly on the gas turbine, they are to be kept
clean, dry, and protected at all times. No lubricant is to be used on carbon seals.
I CAUTION I
•
•
Never mark gas turbine parts with a lead pencil. The
deposits left by the pencil can cause corrosion and
burnout of parts.
Do not mark rotating gas turbine parts using either the
electrolytic-etch or electric-arc-scribe method to
avoid initiation of corrosion conditions.
x.
Use a blue Dykem marker or equivalent. to temporarily mark gas turbine parts. To permanently mark gas turbine parts. use the vibropeen or electric-arc-scribe method on stationary parts, and vapor- or dry-blast method on rotating parts.
y.
Pins and bolts must be installed with heads up. forward. or inboard where possible.
z.
Safety Requirements and Cleanliness.
(I) This manual is intended to provide safe procedures and processes for accomplishing the maintenance
herein described. It is. therefore. important that the Warnings of possible personnel injury, and the Cautions and Notes, be
thoroughly understood and observed by the users of this manual.
(2) Keep dirt and other foreign material out of the gas turbine. Use the recommended covers. caps, and plugs
to seal all openings.
(3)
Place each part on a clean surface as it is removed from the gas turbine.
(4) Wrap small parts in greaseproof paper. seal with tape. and tag (or otherwise identify) the package with the
gas turbine serial number, part nomenclature. and part number.
(5)
Keep related parts grouped together.
(6)
Do not remove wrappings, caps. plugs. or covers until the part is ready to be installed.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
007 00
GEK 99441
Page 10
31 May 2002
5.
MAINTENANCE TECHNIQUES.
a.
Bearing Handling Practices. Removal of bearings from the gas turbine or its components. or both. must be
accomplished with proper tools that are clean and in good condition. During removal, observe the following:
I CAUTION I
•
•
•
Ball and roller bearings require special care to prevent
corrosiOn.
Bearings must not be handled with bare hands or with
any device which might cause contamination.
Clean rubber gloves or a protective cream must be
used at all times when handling bearings.
(I)
Examine assemblies requiring bearing removal carefully to determine the best way to remove the bearing
and to prevent damage to bearing housing or shaft journal.
(2) Remove bearings at earliest possible stage of disassembly to prevent inadvertent damage and contamination. Carefully wipe off loose contamination from face of bearing to prevent it from entering bearing during removal.
(3)
When bearing is to be pressed off shaft. apply pressure to the inner ring.
(4)
When bearing is to be pressed out of housing recess. apply pressure to outer ring.
(5)
when possible.
Apply steady pressure during removal of bearing. Apply pressure evenly around the entire bearing face.
(6) Be careful to keep bearing removal tool straight to avoid damage from cocking. Do not let the bearing
strike the floor or other objects when suddenly released from shaft or housing.
(7)
In cases where gears or other removable parts do not allow the puller to contact the bearing directly, let the
puller jaws contact the gear (or removable part) and remove bearing from shaft.
(8)
All antifriction bearings are part of a matched bearing assembly. Observe the following:
(a)
from the gas turbine.
(b)
Keep components of same matched bearing assembly together at all times when they are removed
If a component of a matched bearing assembly is damaged or lost. replace the complete bearing
assembly.
CAUTION
Do not rotate or spin bearings prior to cleaning: otherwise.
bearings may be damaged.
(c)
Immediately after bearings have been removed, identify them by part number. serial number. and gas
turbine serial number. Place bearings in plastic bags or wrap them in waterproof barrier material.
(9)
Protect bearing journals and housing surfaces as follows:
(a)
Apply preservative coating immediately after bearings are removed.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 994.41
00700
Page 11
31 May 2002
(b)
Protectjournals and housings from handling damage.
(I 0) Handle bearings carefully to avoid unnecessary movement of races and rolling elements as follows:
(a)
Bearings are extremely susceptible to damage: handle bearings with care at all times.
(b) Use same care in handling as that intended on packages marked "FRAGILE". This includes methods
of transporting bearings between areas.
(c) The timeliness of getting bearings to the cleaning and inspection area is also important. Avoid any
unnecessary handling. including axial loading of halls or rollers between the inner and outer races.
b.
Bearing Installation Practices.
(I) Use extreme care during installation of antifriction bearings in a gas turbine. because any damage that
occurs at this time may go undetected until the gas turbine is in operation.
(2)
During installation. to prevent damage and promote longer bearing life, observe the following:
(a)
Assure that bearings arc clean. undamaged, and lubricated, and that all parts are properly mated and
marked.
CAUTION
Do not rotate or spin bearings unnecessarily; otherwise.
bearings may be damaged.
(b)
When installing bearings, use proper tools; tools must be clean and in good condition.
(c)
Do not attempt to install a bearing on a shaft that has not been properly cleaned and given a light coat
of oil. Dirt or chips on a shaft or in a housing can prevent accurate bearing alignment and result in improper operation.
(d) Using aluminum foil. wrap bearings that need to be heated for installation before placing them in an
oven. If a hot oil bath is used to heat bearings, he sure the oil bath is kept clean by constant filtering through a I O-micron filter,
or frequent changing. Be sure that hot bearing is handled in a manner to prevent contamination and damage.
(e)
Do not heat bearings above 250°F ( 121 oq unless otherwise specified.
(f)
Using aluminum foil. wrap bearings that need to be chilled for their installation.
(g) Push bearings into their assembled positions. Do not tap them into position: the series of shocks that
result from tapping can cause permanent damage to the bearings. Dry chilled bearings or races with an air heat gun to prevent
accumulation of moisture, which could cause corrosion.
(h)
Assemble the split races of a split race hearing so that the matchmarks are aligned.
When installing a bearing on a shaft. apply pressure to the inner ring. When installing a bearing in a
(i)
housing recess, apply pressure to outer ring.
(j)
Whenever bearings have been installed, always cover them with clean, lint-free cloth or paper to prevent dust or dirt contamination. Abrasive dust is not easy to see, and enough can collect on a bearing in a short period of time
to eventually cause wear.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 12
c.
Lock-Wiring Practices. Lock-wiring is the securing together of two or more parts with a wire so that any tendency for a part to loosen will be counteracted by an additional tightening of the wire. Observe the following lock-wiring
procedures:
(I)
The common method of installing lock wire (see figure I, sheet I) is two strands of wire twisted together
(called double-strand method). where one twist is produced hy twisting the wires through an arc of 180 degrees and is equivalent to half of a complete turn. Use the single strand method of lock-wiring when so specified. such as in closely spaced.
closed geometrical pattern (triangle, square. rectangle. circle. etc.). on parts in electrical systems. and in other places that
would make the single-strand method more advisable. In such cases, the single strand wire must he limited to the pattern or
group of similar parts.
(2)
The maximum span of lock wire between points must be 6 inches ( 152 mm) unless otherwise specified.
(3) Where multiple groups are lock-wired by either the double-strand or the single-strand method. determine
the maximum number in a series by the nu m her of units that can be lock-wired with a 24-inch (61 cm) length of wire. When
using the double-strand method to lock-wire widely spaced units in a group. not more than three units must be lock-wired in
series (views A and B).
(4)
Pull the wire taut while twisting.
(5) During the twisting operation be sure to keep the wire tight without overstressing it and to prevent it from
becoming nicked. kinked, or otherwise mutilated (except that abrasions normally caused by commercially available wire
twister pliers are acceptable).
(6) Do not lock-wire so as 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.
(7)
Wiring must he done through the holes provided. If no wire hole is provided. wiring should be to a convenient neighboring part in a manner not to interfere with the function of the parts (see views A, D. and E. sheet 2).
(8)
Always use new lockwire for each application.
(9) Various examples of lock-wiring arc shown in sheets I and 2. Although every possible combination is not
shown. any combination used must adhere to the basic rules outlined in this procedure. View K (sheet I) shows the singlestrand method. while the other views show the two-strand or double-twist method.
(I 0) For use up to 700°F (371 °C) use stainless steel or equivalent for lock wire material. For use up to I ,800°F
(981 °C), use a corrosion and heat resistant alloy or equivalent. Lock wire of 0.020 inch (0.51 mm) thick and 0.032 inch
(0.81 mm) thick may be used, with choice determined hy the size of the hole in the part being lock-wired. Where a choice is
possible. use 0.032 inch (0.81 mm) thick lockwirc.
( 11) Check the parts to be lock-wired to make sure that they have been correctly torqued. Undertorquing or
overtorquing to obtain proper alignment of the holes is not permitted. If it is not possible to obtain a proper alignment within
the specified torque limits, loosen the part and try again. or select another neighhoring part.
(12) In adjacent units. it is undesirable that the holes be in approximately the same relationship to each other.
The proper relationship is shown in views A. B. C. D (sheet I) for right-hand threads. Install lockwire so that the strand
through the hole will have a tendency to pull the unit clockwise. Reverse for left-hand threads.
( 13) Insert the lock wire through the first unit and bend the upper end either over or around the head of the unit.
If bent around it, the direction of wrap and twist of the strands must be such that the loop around the unit comes under the
strand protruding from the hole so that the loop will stay down and not tend to slip up and leave a slack loop (view A. sheet I).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 13
RIGHT-HAND
TNIST
VIEH B
VIEH A
VIEH E
VIEH C
VIEH G
YIEH F
VIEH D
VIEH H
NOTE
•
•
VIEHS A THROOGH H SIKJC METHODS FOR HIRING VARIOOS STANDARD ITEMS.
HIRE MAY BE HRAPPm OVER THE UNIT RATHER THAN AROOND, AND SHOOLD
BE HRAPPm OVER THE UNIT 011 TAPERm HEAD BOLTS.
VIEH K
CORRECT METHOD FOR HIRING BOLTS
IN DIFFERENT PLANES. NOTE THAT
THE HIRE SHOOLD BE INSTALLm SO
THAT TENSION IS IN THE TIGITENING
DIRECTIOII.
NtEN PRACTICABLE, HOI.l.Ot HEAD
PUJGS SHOOLD BE HIRm AS SltotN
HITH THE PIGTAIL BENT INSIDE
THE HOLE TO AVOID SNAGS AND
POSSIBLE INJURY TO PERSONNEL.
CORRECT APPUCATIOII OF SINGLE HIRE
TO QDSELY SPACED JIJLTIPLE GROUP.
1200986-00-A2A
Figure I.
Lock-Wiring Practices (Sheet I of2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 994.41
007 00
Page 14
31 May 2002
g
.
.
FIXED
PART
ROTATING
PART
BOLT HIRED TO A RIGHT ANGLE BRACKET
HITH THE HIRE HRAPPED AROOHD THE
BRACKET.
CORRECT METHOD FOR HIRING
ADJUSTABLE CONNECTING ROD.
ARROf SHOtS TIGHTENING
DIRECTION OF JAMNUT.
VIEH A
CORRECT METHOD FOR HIRING THE
COUPLING NUT ON FLEXIBLE LINE
TO THE STRAIGHT CONNECTOR
BlAZED ON RIGID TUBE.
VIEM C
VIEH B
VIEH E
CORRECT METHOD FOR l.OCKHIRING FITTINGS IIIERE NO LOC»>IRE LUG IS
PROVIDED. BE SURE THE MIRE IS
TIGITLY HRAPPED AROUND FimNG.
OOUPUNG NUTS ON A TEE MUST BE
HIRED SO THE TENSION IS AI..MAYS
IN THE TIGHTENING DIRECTION.
SMALL al.IPUNG 11JTS OR THOSE MADE
OF SOFT MATERIAL MAY BE HIRED AS
SHOIIf TO LESSEN POSSIBIUTY OF
MIRE BREAKING OR TEARING OUT.
END VIEH (ENLARGm)
VIEH G
VIEM H
VIEM I
al.IPUNG NUTS ATTACHED TO STRAIGHT CONNECTORS ti.IST BE HIRED
AS SI!Otlt MHEN HEX IS AN INTEGRAL PART OF THE CONNECTOR.
1200967-00-A2A
Figure I.
Lock-Wiring Practices (Sheet 2 of2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 15
(14) Pull the wire to keep it taut and twist the strands until the twisted part is just short of a hole in the next unit.
The twisted portion should be within 1/8 inch (3.2 mm) from the hole in either unit. There should be 9-12 twists per inch
(25.4 mm) for the 0.020 inch (0.51 mm) thick lock wire and 7-10 twists per inch (25.4 mm) for the 0.032 inch (0.81 mm) thick
lock wire.
( 15) If the free strand is to be bent around the head of the second unit, insert the uppermost strand through the
hole in this unit. and follow the procedures in step ( 13 ). (Refer to center unit of view A, sheet I). 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 above
procedure.
( 16) After lock-wiring the last unit. continue twisting the wires to form a pigtail of three to five twists
1/4-1/2 inch (6.4-12. 7 mm) long and cut the excess wire. Bend the pigtail toward the part to prevent it from becoming a snag.
( 17) When lock wire holes are drilled across comers. use method illustrated in view G (sheet 2) in preference to
other methods.
d.
Cotter Pin Practices. (See figure 2).
(I)
Cotter pins are used to restrain motion between two parts by inserting the cotter pin through a hole in the
part and spreading the exposed ends.
(2)
Cotter pins are not reusable and must be replaced after removal.
(3)
Refer to view A for the proper method of installing cotter pin into clevis pin.
(4) Refer to view B for the preferred method of installing cotter pin into locking nut. Use the alternative
method (view C) only if there is lack of clearance.
Positioning and Non-Positioning Type Fittings Installation Practices. Positioning-type fittings (sec figure 3,
c.
views A and B) are bulkhead tees, elbows, and similar fittings. Non-positioning-type fittings (view C) are nipples. plugs,
reducers. bushings. etc. The following procedures provide instructions for installing positioning and non-positioning type
fittings:
(I)
Tighten plugs and tube fittings. Assembly techniques vary, depending upon the specific type of plug or
tube fitting being used. These types include non-positioning plugs and unions. using packings. or other compressible packings
for seals; positioning fittings. with or without backup washers; and universal bulkhead fittings. held in position by locknuts.
(2)
Do not use lubricant on plugs and tube fittings unless specified. Do the following:
(a) If lubrication is needed. use same fluid that the system uses; for air hoses or tubes, use petrolatum or
pneumatic system grease.
(b)
When lubrication is specified, apply a thin coating to male threads only.
(3) When installing non-positioning fittings (view C). lubricate the packing lightly to prevent cutting by sharp
threads. Do the following:
(a)
Assemble fitting and packing so that the packing is seated evenly in groove of fitting.
(b)
Thread the fitting into boss and tighten to the appropriate torque value.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
007 00
GEK 99441
Page 16
31 May 2002
STEP 1
INSTALL THE COTTER PIN
WITH THE AXIS OF THE EYE
PARALLEL TO THE SHANK
OF THE CLEVIS PIN.
STEP 2
BEND THE PRONGS OF THE
COTTER PIN AROUND THE
SHANK OF THE PIN AS
ILLUSTRATED.
COTTER PIN HEAD /
SNUG TO SHANY
NOT DEFORMED.
-
VIEW A
LOCKING CLEVIS PINS
VIEW B
LOCKING NUTS
(PREFERRED INSTALLATION)
COTTER PIN
LOCKING NUTS
(ALTERNATIVE INSTALLATION}
STEP 1
INSTALL THE COTTER PIN
WITH THE HEAD SEATED FIRMLY
IN THE SLOT OF NUT WITH
THE AXIS OF THE EYE AT RIGHT
ANGLES TO THE STUD SHANK.
STEP 2
BEND PRONGS SO THAT THE
HEAD AND UPPER PRONG
ARE FIRMLY SEATED AGAINST
THE STUD.
1200988-00-A2A
Figure 2.
Cotter Pin Practices
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
007 00
GEK 99441
31 May 2002
Page 17
POSITIONING TYPE FITTING
PACKING
BOSS
BEFORE TORQUING
AFTER TORQUING
VIEW A
VIEW B
NON-POSITIONING TYPE FITTIKG
VIEW C
1200989·00-A2A
Figure 3.
Installation of Positioning and Non-Positioning Type Fittings
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
007.00
31 May 2002
Page 18
(4) When installing positioning fittings (no hackup washers) (view A), thread the locknut completely over the
first section of threads on the fitting, past the packing groove, and onto the second section of threads as follows:
(a) Luhricate packing. Carefully install packing over first section of threads and into the packing groove
so that the packing is seated evenly against the second section of threads.
(h)
Tighten locknut until it touches the packing.
(c)
Install fitting in boss so that packing touches the countersunk surface.
(d)
Turn fitting to desired position by backing out not more than one turn.
(e)
Hold fitting in position and tighten locknut to the appropriate torque value (view B).
(5) When installing positioning fittings (with backup washer) (view A). thread the locknut completely over the
first section of threads on the fitting. and onto the second section of threads so that the backup washer recess faces the packing
groove as follows:
(a)
Grip the backup washer firmly by its outside edge. and thread the fitting into the cupped washer.
(b)
Do not use any lubricant.
(c)
Continue threading the washer onto the fitting until the washer is free on the packing groove.
(d)
Pick up any slivers of plastic material cut from the washer.
Press the edges of the washer into the recess in the locknut until evenly seated. making sure that
(e)
threads of litting do not interfere with seating of washer.
(f)
f.
Lubricate and install packing as directed in step (3).
Preformed Packings Installation Practices.
Lubricating Oil
66
l CAUTION I
Do not lubricate preformed packings used in electrical connectors. Oil will damage connectors.
(I)
Apply a light coating of lubricating oil or petrolatum to all packings unless some other lubricant is specilied. Do not lubricate packings that are installed in electrical connectors. Oil will damage connectors.
(2) Before installing packings and parts containing packings, lubricate all grooves. lead-in chamfers, bores,
and surfaces with lubricating oil. Wipe off excess oil before assembling parts.
(3) Do not reuse packings or gaskets that were exposed or removed during disassembly. Use new packings
and gaskets at final assembly unless reuse is specifically specified.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
007 00
GEK 99441
31 May 2002
g.
Page 19
Lubricants.
CAUTION
Molykote, graphite-type compounds or any other antiseize
compound must not be used to lubricate a surface that will
come in contact with lubricating oil or contamination may
result.
(I)
Be sure all surfaces requiring lubrication are clean and free of moisture, solvents, and other contaminants
before applying the lubricant.
(2) Do not apply a lubricant over a corroded surface. During handling. do not contaminate highly-finished surfaces with body moisture or other agents prior to lubricating: such contamination could cause corrosion after lubricant is
applied.
(3) Lubricating oil MIL-L-23699 or MIL-L-7808 is the type of oil meant wherever the term "light coat of oil"
or the word ''oil" is used in assembly procedures.
Antiseize Compound
Braycote 655
416
(4) Unless otherwise noted. lubricate threads of bolts, screws, studs, coupling nuts and fasteners used in the
assembly of parts with a light coat of anti seize compound (Braycote 655 ). Failure to do this may cause bolts to be improperly
torqued or cause shank nuts to become loosened during assembly, and may cause bolt seizure or failure or both during
removal.
h.
Spectrometric Oil Analysis Program (SOAP). A method used to monitor and evaluate the condition of the oillubricated parts of the gas turbine. This is done by making a spectrometric analysis of oil samples taken from the gas turbine
at regular intervals. The extent of wear is determined by the amount and type of wear metals found in the oil (refer to
WP 015 00 for procedure).
i.
Torque-Tightening Practices. Torque is expressed in pound-inches (lb in.) or in pound-feet (lb ft). One poundfoot is the twisting force of one pound applied to a lever one foot long: torque values are equal to the pounds of force times the
length of the lever (wrench) in feet or inches. The specified twisting force (torque) is applied to threaded fasteners, such as
nuts or bolts. to obtain optimum security of the part within the tensile limits of the material or within the shear limits of the
threads or the fastener. Unless otherwise specified, lubricate all fastener threads and washer faces with a light coat of antiseize
compound (Bray cote 655 ). Tighten fasteners to a specified torque value as follows:
I CAUTION I
When gas turbine parts have been chilled or heated during
assembly. do not torque locknuts or retaining bolts until part
returns to room temperature. If part has been heated. fastener may loosen as part cools. If part has been chilled, fastener may be overstressed as part expands.
(I)
Tighten at a uniformly increasing rate until desired torque is obtained. In some cases. where gaskets or
other parts cause a slow permanent set. be sure to hold torque at desired value until material is seated. For example:
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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Page 20
Required torque = 135 lh in.
Etlective length of torque wrench (L) = I 0.0 inches
Effective length of crow foot (E)= 1.5 inches
Then:
(Required torque) x (L) = 135 x I 0 = 1350
L+ E = 11.5 inches
1350
11.5 = 117.41h in.
Thus: A gage reading of 117.4 lh in. indicates a required torque of 135 lh in.
(2) It is not desirable to tighten to the final torque value during the first drawdown: uneven tension can cause
distortion or overstressing of parts.
(a)
Seat and torque mating parts by tightening bolts or nuts gradually until parts are firmly seated.
(h) Loosen each bolt or nut separately and apply final torque. Tightening in a diametrically opposite
(staggered) sequence is desirable in most cases.
(c)
Do not exceed listed maximum torque values given in this manual.
NOTE
This procedure also applies to gas turbine parts which are
bolted similar to the circumferential flanges (for example.
the exhaust frame centerhody).
(3) When applying torque to a series of bolts, select a medium value. If some bolts in a series are torqued to a
minimum value and others to a maximum. force is concentrated on the tighter bolts and is not distributed evenly. Such unequal
distribution of force may cause bolt failure. Torque flange bolts as follows:
(a)
Torque two bolts (each mounting flange) 180° apart.
(b)
Torque two bolts (each mounting flange) 90° from the first bolts that were torqued.
(c)
Torque remaining bolts.
(4) When installing key washers. torque locknut to minimum value and then try keywasher in all possible positions. If slots and tabs on keywasher will not align, increase torque on locknut. not to exceed maximum torque.
J.
Torque Wrench Sizes. The torque wrenches listed below are recommended for use within the indicated limits.
Larger wrenches have a wider tolerance, and their use can result in serious inaccuracies.
Torque
Wrench
Size
30 lh
150 lh
600 lh
150 lh
250 lh
1000 lh
(3N·m)
in.
in. (17 N·m)
in. (68 N·m)
ft (200 N·m)
ft (340 N·m)
ft ( 1360 N·m)
Torque Limits
0-25 lh in.
25-140 lh in.
140-550 lh in.
30-140lhft
140-240 lh ft
240-1000 lh ft
(0-2.8 N·m)
(2.8-15.8 N·m)
(15.8-62.1 N·m)
(40.7-189.8 N-m)
( 189.8-325.4 N·m)
(325.4-1355.8 N·m)
Tolerance
± I lh
± 5 lh
±20 lh
± 5 lh
±10 lh
±20 lh
in. (0.1 N·m)
in. (0.6 N·m)
in. (2.3 N·m)
ft (6.8 N·m)
ft (13.6 N·m)
ft (27.1 N·m)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
00700
31 May 2002
Page 21
k.
Offset Extension (Crowfoot) Wrench. When a crowfoot extension is used with a torque wrench, the effective
length of the torque may be changed. The torque wrench is so calibrated that when an extension wrench is used, the indicated
torque (the value that appears on the scale or dial of the torque wrench) may be different from the actual torque that is applied
to the nut or bolt. Therefore. when a crowfoot extension is used, the torque wrench must be preset to compensate for the
increase or decrease in actual torque as compared to indicated torque.
I.
Offset Extension (Crowfoot) Wrench Computations. (See figure 4.) The addition or subtraction of the effective
length of the crowfoot extension (E) is determined by its position on the torque wrench (L). When the extension wrench is
pointed in the same direction as the torque wrench. add the effective length of the extension to the effective length of the torque
wrench (L +E). When the extension is pointed back toward the handle of the torque wrench, subtract the effective length of
the extension from the effective length of the torque wrench (L-E). When the extension is pointed at right angles to the torque
wrench. the effective length does not change. The effective length of the torque wrench is a variable. and a different figure
must be used for each type of torque wrench. The effective length of the crowfoot extension is determined by measuring from
the center of the drive opening to the center of the wrench opening. Multiply the required torque by the effective length of the
torque wrench (L). Divide this product (L +E) or (L-E) as determined from figure 4. The quotient is the gage or scale reading required to obtain the desired torque.
6.
GENERAL INSPECTION INSTRUCTIONS.
a.
Shop Practices. Parts or assemblies designated as matched sets will be maintained as a matched set. Set numbers. part numbers. and serial numbers will be protected during cleaning or repair to prevent removal. When identification is
removed or is no longer legible. re-mark the part.
b.
Evaluation of Gas Turbine Part Serviceability Using the Borescope. Where no comparative dimensions are
given. evaluation must be accomplished using good judgment and acquired knowledge/experience with the equipment. Borescope views of some parts are limited due to the physical configuration of the hardware. In these instances judge the condition
of the remaining parts/areas on the condition of the visible parts. Information on the operation and use of the borescope as
applied to the gas generator/power turbine, and when and what to inspect with the borescope is given in Work Package 0 I 0 00.
Inspection limits of compressor blades and vanes, combustion liner, and high-pressure turbine blades are also given in
WP 010 00.
c.
Extent and Methods of Inspection. Damage can be evaluated only by thorough inspection. Inspection for
defects should be visual. without the aid of magnification or the use of special processes such as fluorescent penetrant or magnetic-particle.
d.
Definitions of Inspection Terms. Definitions of inspection terms used in this manual are listed in table 2. The
first column lists terms generally used to describe deviations from normal conditions in gas turbine parts. The second column
lists definitions which, although not technically identical. are related since the damage they describe is similar in origin or in
appearance. The third column lists probable causes.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
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____________
WHEN USING A TORQUE WRENCH ADAPTER WHICH
CHANGES THE DISTANCE FROM THE TORQUE WRENCH
DRIVE TO THE ADAPTER DRIVE, APPLY THE
FOLLOWING FORMULAS TO OBTAIN THE CORRECTED
TORQUE READING,
ADAPTER
DRIVE
CENTERLINE
L
.-----LEGEND-----,
T =ACTUAL !DESIRED) TORQUE
V-APPARENT IINDICATEDJ TORQUE
L =EFFECTIVE LENGTH LEVER
E=EFFECTIVE LENGTH OF EXTENSION
TORQUE
TORQUE WRENCH
HANDGRIP
CENTERLINE
IPIEDETERMINEDJ
WRENCHl
WRENCH
DRIVE
-CENTERLINE
WRENCH
DRIVE
CENTEILINE
HANDGRIP
CENTERLINE
ADAPTER\
DRIVE
QNTERLINE
1------ l ----fORMULA
M
=- y
FORMULA
EXAMPLEr (WITH "E" AS PLUS DIMENSION)
T = 135 ll IN.
Y= 135a10
10 1.5
+
=
1350 ... 117 4
11.5
•
EXAMPLEa CWITH '"E" AS MINUS DIMENSION)
T- 135 Ll IN.
Y =UNKNOWN
Y -= UNKNOWN
L = 10.0 IN.
L = 10.0 IN.
E = 1.5 IN.
Y == 117 Ll IN.
-l!.i.
L-E = Y
E- 1.5 IN.
135 a 10
1350
1.5 =
a.s= 158.1
y = 10
Y- 159 L1 IN.
NOTE
A CORRECTED TORQUE READING IS NOT REQUIRED
WHEN AH ADAPTER IS USED WHICH DOES HOT CHANGE
DIMENSION •L•. DO NOT USE AHANDLE EXTENSION
ON ANY TORQUE WRENCH.
ALL DIMENSIONS
ARE IN INCHES
1200990-00·A2A
Figure 4.
Offset Extension Wrench (Crowfoot) Computations
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Page 23
TABLE 2.
DEFINITIONS OF INSPECTION TERMS
Term
Definition
Probable Causes
Abrasion
Roughened surface. May vary from light to severe.
Foreign material between
moving parts.
Bend
Distortion in a part. Curvature out of proper contour.
Severe application of heat or
excessive force.
Blister
Raised portion of a surface. usually where the surface has
separated from the base. Generally found on surface-treated
parts (plated or painted surfaces).
Poor original bond with base.
Possible aggravation by heat
or pressure.
Break
Separation of part.
Severe force. pressure. or
overload.
Brinelling
Indentation of the surface, usually found on ball or roller
bearings.
Incorrect assembly or disassembly procedure used on
bearings, or application of
excessive force on bearing.
Brittleness
Loss of resiliency is parent metal.
Severe application of heat.
cold. or possible chemical
action.
Buckling
Large deformation of the original contour: a bulge in a
surface.
Severe pressure, impact of a
foreign object, or heat
distortion.
Bulge
A raised portion or outward swelling on surface.
Internal pressure.
Bum
A rapid, destructive, oxidizing action. Change in color and
appearance often indicates this condition.
Part subjected to higher temperatures than the parent
material can withstand
structurally.
Burnishing
Smoothing of a metal surface by mechanical action. but
without a loss of material; generally found on plain hearing
surfaces. Surface discoloration is sometimes present around
the outer edges. Normal burnishing from operational service is not detrimental if coverage approximates the carrying load and if there is no evidence of burns.
Operation of mechanical
parts.
Burr
Rough edge or sharp projection.
Excessive wear or poor
machining.
Chafing
A worn or rubbed area caused by friction.
Wear produced by fuel, lube,
and air tubes rubbing against
other parts.
Chatter Mark
Surface irregularity.
Machining process.
Chipping
Breaking away of small metallic particles.
Heavy impact of foreign
object.
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Page 24
TABLE 2.
DEFINITIONS OF INSPECTION TERMS (Cant)
Definition
Term
Probable Causes
Coking
Buildup of carbon deposits.
Deterioration of lubricants or
incomplete combustion.
Cold-work
The rework of metal parts at room temperature. using hand
tools. The removal of dents in sheet metal parts.
Corrosion
Formation of many small pits which cumulatively create a
wide cavity (usually shallow) in surface of part.
Oxidation of particles.
Crack
Parting of parent material or of metal in a welded zone, with
or without deformation of adjacent areas.
Severe stress from overloading or shock: possible extension of a scratch. Also caused
by thermal expansion. vibration. and material fatigue.
Crazing
A mesh of minute hairlike cracks found in glazed or bakedon coated surfaces which do not penetrate into parent metal.
Temperature changes or
deformation of parent metal.
Dent
Smooth surface depression. Material is displaced. but not
separated.
Careless handling or striking
the part: operational wear
with foreign-object
interference.
Deviation
A condition which causes a part to differ from the manufacturer's drawing.
Wear. rework, etc.
Erosion
The gradual wearing away of material.
Sand or corroding gas or
liquids.
Fatigue Failure
Progressive yielding to repeated stress of one or more local
areas. aggravated by the cumulative effect of scratches.
sharp indentations. cracks, tool marks and inclusions. As
the stress is repeated, cracks develop, then spread, usually
from the surface (or near the surface) of the particular section. Finally, so little material remains that the normal
stress on the part exceeds the strength of the remaining
material. This results in separation. It is not caused hy
metal crystallization and can easily be determined by visual
inspection of the part. There will he evidence of several
more or less concentric lines. The center (or focus) of the
lines indicates the origin of the failure.
High alternating stress.
Cracks. tool marks, sharp
comers. nicks. galling. inclusions, corrosion. and insufficient tightening of studs or
bolts increases the possibility
of fatigue failure.
Flaking
Pieces of a plated or painted surface breaking away.
Imperfect bond or severe
load.
Fracture
Separation of part.
Severe force, pressure, or
overload.
Fretting
Loss of fine particles of metal.
Rubbing action between
parts.
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TABLE 2.
DEFINITIONS OF INSPECTION TERMS (Cant)
Definition
Term
Probable Causes
Galling
Accumulation of foreign material deposited on surfaces.
Movement of two surfaces in
contact with one another
under severe pressure.
Glazing
Covering of hard. glossy surface on plain bearing areas
(sometimes a desirable condition).
Pressure. oil. and heat in
combination.
Gouging
Wide. rough scratch or group of scratches, usually accompanied by one or more sharply impressed corners, and
sometimes by deformation or removal of material.
Presence of a rather large foreign body between parts in
motion.
Grooving
Long. narrow. continuous channels having no sharp edges.
Concentrated wear due to
abnormal relative motion of
parts.
High Metal
Displaced surface metal.
Nicks. scratches. gouges or
dents.
Hot Gas Corrosion
(Sultidation)
The corrosion of unprotected metal (with no coating) that
has been exposed to hot gases. When first exposed, the surface becomes rough and appears to be pitted and pockmarked. Also, there is a noticeable difference in the colors
of the exposed and unexposed surfaces. Further exposure of
surface to hot gases causes it to blister and. in time. to flake
off in layers.
This kind of corrosion differs
from that normally found on
surfaces attacked only by salt
in the atmosphere. In hot gas
corrosion. the hot gases convert sulphur oxides to sulfates
in the presence of salt. The
metal is attacked by the
resulting deposits.
Hot Spot
Heat blueing of metal on the external surfaces of combustion chamber frame or combustion liner.
A defective fuel nozzle (poor
spray pattern) causing uneven
burning of fuel in combustion chamber.
Imbalance
The state of being out-of-balance. An unequal distribution
of weight about an axis of rotation.
Improper assembly of parts.
shifting. damage, etc.
Inclusion
Foreign material impressed into a surface generally indicated by dark spots or lines.
Inherent porous condition in
the material.
Looseness
Abnormal movement of a part.
Wear. improper assembly. etc.
Misaligned
A mismatching or malformation of any parts which either
prevents perfect assembly or results in faulty operation or
ultimate part failure, or both.
Wear. damage, using wrong
parts. etc.
Missing Piece
Removal or loss of a portion of parent material due to a
combination of defects or damage.
Breaking away of material.
burnout. wear, rust, shearing.
Nick
Sharp indentation. The parent material is displaced but usually not separated.
Negligent handling of parts or
foreign-object damage during gas turbine operation.
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Page 26
TABLE 2.
DEFINITIONS OF INSPECTION TERMS (Cant)
Term
Definition
Probable Causes
No Apparent Depth
Term used to describe surface defects that can be seen visually with a white light. but can not be felt with fingernail or
with a scriber.
Noisy
An abnormal sound condition of moving parts, usually an
increase in volume or change in pitch.
Damaged working parts, misalignment of parts. etc.
Obstruction
Prevention offree flow of air or a fluid (oil. fuel, water)
through the flow path.
Foreign material in the flow
path, malformation in the
now member.
Oxidation
A surface deterioration that forms as red rust in iron and
low-alloy steels at ambient temperatures. The oxides which
form on super alloys are complex and can be green or black
depending on material composition and temperature at
which it is formed.
The chemical reaction
between oxygen in the air and
the metal surface.
Parent Metal
The basic metal of a part. sometimes referred to as base
metal; the term is used particularly in connection with welding, where the parent metal is that being welded rather than
that used in the welding rod.
Peening
Surface deformation.
Foreign object damage.
Pick up
Transfer of one material into or upon the surface of another.
Insufficient lubrication.
unbroken edges of pressfitted parts. Seizure of rotating parts during operation.
Improper manufacture.
Pinched
Distortion of one or more surfaces of the parent metal.
External pressure on part.
Pitting
Minute depression or cavities, without sharp. high-stress
corners.
Chemical action. oxidation of
surface. electrolytic action.
Rub
A surface cavity or impression.
Two surfaces moving against
each other.
Scoring
Deep, multiple scratches or elongated gouging.
Presence of metal chips
between loaded surfaces that
have relative motion.
Scratch
Long. narrow, sharp-cornered impression.
Two surfaces moving against
each other.
Scuff
A series of small superficial or shallow scratches.
Wear.
Seizure
A binding of two surfaces which prevent further movement.
Parts failure, shifting of parts,
foreign objects.
Sheet Metal Dent
A large. smooth depression in the parent metal.
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TABLE 2.
DEFINITIONS OF INSPECTION TERMS (Cont)
Definition
Term
Probable Causes
Spalling
Sharply roughened area characteristic of progressive chipping or peeling of surface material.
Spot-Welding
A resistance-welding process in which parts are held
together under pressure by electrodes. When the current is
turned on, the resistance-to-flow set up by the part creates
enough heat to fuse the parts together. Size and shape of
spot welds are determined by the size and shape of the
electrodes.
Tack Weld
A weld made to hold parts in proper alignment until final
welding is done. The weld or tacks are made small enough
to allow parts to be broken apart if desired.
Varnish Film
A hard surface-film on metal; straw-color to dark brown.
Exposure to dry chemicals or
fluids (commonly oil) while
the part is heated above the
breakdown point of the chemical or fluid.
Warped
Not true in plane or in line; out of true shape.
Overstressed, damaged.
Wear
Relatively slow removal of parent material from any cause;
frequently not visible to the naked eye.
Chafing, chattering, erosion.
oxidation. rubbing, scraping
or scuffing.
e.
Surface cracks. inclusions. or
similar surface damage that
causes a progressive breaking away of the parent
material.
Organization of Inspection Data.
(I)
Inspection data for individual parts consists of procedures listed in table format. and related illustrations of
(2)
Inspection tables are arranged as follows:
the parts.
(a)
Inspect Column- Each part listed in this column must be inspected for specific defects. For example,
if wear is listed. the applicable limit refers only to wear. Other defects. even though related to wear (galling. pick up, fretting,
etc.). are listed separately. Unless otherwise indicated. inspect defects visually.
(b) Usable Limits Column -This column lists the allowable limits for specific defects. If a defect is
within these limits. the part does not require corrective action. If the limit is exceeded and if the defect cannot be repaired.
replace the part.
(c)
Max Repairable Limits Column- This column. which appears in all inspection tables except those
with borescope data, lists the limit that is allowable if the defect is to he repaired according to the instructions in Corrective
Action column. This limit is always greater than the limit listed in the Usable Limits column.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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Page 28
(d)
Corrective Action Column- This column specifies the action to be taken if the maximum repairable
limit is exceeded.
f.
Crack Description. The following terms are generally used to describe cracks:
NOTE
The heat-affected zone in a welded area is the area in which
the micro-structure of the material and/or its physical characteristics arc affected by the heat of the welding. Cracks in
the heat-affected zone will be considered weld cracks.
Cracks outside the heat-affected zone will be considered
parent metal cracks.
•
•
•
•
7.
Axial: General direction parallel to the centerline of the gas turbine
Radial: General direction perpendicular to the centerline of the gas turbine
Transverse: General direction perpendicular to the length of the weld
Longitudinal: General direction parallel to the length of the weld.
STANDARD MAINTENANCE PRACTICES.
a.
Cold-Working. Cold-working is a practice in which materials are reworked to original contour (as removal of
dents). This procedure is used to repair parts (mostly sheet metal) which have been damaged or changed from their original
contour. No heat is applied to the material.
(I)
Inspect the part to be repaired.
(2) Using plastic or other soft-faced mallets, pliers and similar hand tools, return the part to its original contour
within usable limits specified in manual.
b.
(3)
After cold-working, inspect the reworked area for cracks, observing limits in manual.
(4)
Compare the repair part with a similar undamaged part.
Blending Procedures.
(I)
Blending (see figure 5) is a repair procedure that is used to remove stress concentrations caused by nicks,
scratches, or other sharp-edged damage marks on 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.
(2) 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.
(3) Defects more than 0.25 inch (6.4 mm) apart must be blended separately. Those less than 0.25 inch
(6.4 mm) apart must be blended together.
(4)
The finish on the blended area must be as close as practical to the original finish of the part.
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Page 29
DEFECT WITH
HIGH METAL
I
DEFECT
DEFECT BLENDED
BLENDING OF ADEFECT
Figure 5.
(5)
HIGH METAL REMOVED
REMOVAL DF HIGH METAL
Blending and High Metal Removal
Hand Blending.
(a) Sharp edges can be blended out. using abrasive stones or papers. files, or crocus cloth. Coarse grades
of abrasives or tiles 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.
(b) When blending compressor rotor blades, stator vanes. turbine blades. and similar parts, blend in a
radial direction in relation to the gas turbine. Avoid removing metal from leading and trailing edges or airfoil sections in such
a way that the edges become thin or sharp; blend so as to maintain approximately the original contour.
(c)
(6)
When blending a cylindrical part. blend in a circumferential direction, not along the axis of the part.
Power Blending.
(a) Blending on most parts may be done by using a power-driven polishing wheel or rubber-bonded
abrasive points. Any special instructions for the individual part must be followed.
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Page 30
I WARNING I
Power Grinding
•
•
•
•
Avoid prolonged or repeated contact with dust. Inhalation of dust may cause temporary coughing and
wheezing. respiratory tract irritation. and permanent
lung problems. If coughing or wheezing persists, get
medical help.
If dust contacts eyes. flush them thoroughly with
water.
When using an air-exhausted grinding wheel, wear
approved respirator, goggles. or face shield.
If grinder is not equipped with local exhaust ventilation. wear an appropriate respirator and goggles or
face shield.
CAUTION
When doing power blending, be sure to avoid building up
excessive heat to avoid thermal stresses in the part.
(b) 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.
After power blending of a titanium part is completed, hand blend the same area approximately
(c)
0.002 inch (0.05 mm) deeper to remove any residual stresses in the surface material.
(7)
Blending Minor Indications in Tubing.
(a)
Use a fine abrasive stone, a small file, emery cloth or crocus cloth for blending.
(b) Blend around the circumference of the tubing. The finished blend must be as close as practical to the
original tin ish of the part.
(8) Removing High Metal. High metal is caused by the displacement of metal above a surface. It is found
around defects such as nicks and scratches. Remove high metal as follows:
(a)
Use a fine abrasive stone. a small file. emery cloth. or crocus cloth to remove high metal
(b)
Remove only the material that is projecting above the original surface contour.
(see figure 5).
c.
White-Light Inspection.
(I)
This method of inspection is to be used on parts that have many sheared openings, such as a combustion
liner. because it is difficult to determine the difference between shear marks and cracks using fluorescent penetrant inspection
method.
(2) Operational cracking of parts having sheared openings is caused by thermal fatigue. This type of crack is
easily seen using white light inspection method. The white light inspection is also used to inspect parts for defects that are visible to the naked eye or with 5X to I OX magnification.
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31 May 2002
(3)
Page 31
White-light-inspect parts as follows:
(a) Inspect the part for cracks under a bright white light ( 150-watt standard spotlight or equivalent).
Hold light within 4 feet ( 1.2 meters) of the surface hcing inspected.
(h) Inspect each area where cracks are suspected (using 5X to IOX magnification) to verify that there is
a defect and to determine its course and length.
(c)
d.
Mark each unacceptable defect along its entire length (in the crack). using a hlue Dykem marker.
Alodine 1200 Touchup.
NOTE
The Alodine No. 1200 process is used to touch up and protect reworked and corroded aluminum surfaces. It can he
used in place of anodizing and is either brushed or sprayed
onto the part. Alodine No. 1200 solution is a thin, golden
and iridescent coating. The color may vary with different
aluminum alloys.
Phosphoric Acid, 0-0-670
5
(I)
Clean part using phosphoric acid. Keep part wet with phosphoric acid I to 5 minutes.
(2)
Rinse part thoroughly with clean water.
(3)
Mix Alodine solution as follows:
Chemical Conversion Materials
for Coating Aluminum and
Aluminum Alloys, MIL-C-81706
281
I CAUTION I
•
•
Do not use lead or glass containers for mixing or storing the solution.
Be sure Alodine solution does not come in contact
with steel parts.
(a) Add 3 ounces (85 grams) of Alodine No. 1200 powder to each gallon (3.8 liters) of water. Stir mixture until powder is dissolved.
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Nitric Acid, 0-N-350
4
(b) Add I /2 fluid ounce ( 15 cc) of concentrated (70 percent) nitric acid per gallon (3.8 liters) of solution.
and stir thoroughly. Do not add wetting agents or any other material to this solution.
NOTE
A small amount of material may settle out of the solution:
however. it can be disregarded.
(c) Let the solution stand for a minimum of I hour before use. Store surplus solution in polyethylene
bottles or stainless steel containers.
(4)
Brush or spray the Alodine No. 1200 solution on the surfaces of the part and allow solution to set for 3 to
(5)
Remove the excess Alodine with a wet cloth or sponge and rinse the part thoroughly in water.
(6)
Allow Alodine coating to air-dry.
(7)
Inspect the refinished area. The finish must appear adherent and free from dust.
5 minutes.
e.
Vapor Degreasing.
CAUTION
Do not vapor-degrease titanium or titanium parts. bearings,
rubber or plastic parts which can be attacked by organic
solvents.
(I) General Information. Vapor degreasing is a cleaning method designed to remove oil, grease and preservative compounds from metal by solvent vapor. Part is immersed in vapor so that when vapor condenses on metaL grease. oil and
preservative compounds are carried away. When part reaches temperature of vapor. cleaning action ceases. If further degreasing is necessary. part must be cool before returning to vapor degreaser.
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Trichloroethane, 0-T-620
Trichlorotrifluoroethane,
MIL-C-81302
Tetrachloroethylene
(Perchloroethylene), 0-T-236
(2)
122
124
99
Materials and Equipment.
(a) Solvents recommended for vapor degreasing, in order of preference, are: trichloroethane 0- T- 620,
trichlorotrif1uorethane MIL-L-81302, and tetrachloroethylene (perchloroethylene) 0- T-236. These solvents are used to clean
metal by the vapor method. Their high vapor density makes it possible to use these solvents with only a small vapor loss.
(b) A flat bottom tank with heating coils installed at bottom, and cooling coils installed internally midway around tank to prevent escape of vapors. A tank cover should also be provided to prevent escape of vapors when tank is
not in use. The level of the solvent in tank should be kept 2-4 inches (51-1 02 mm) above heating coils at all times.
(3)
Procedure.
(a)
Suspend part to be cleaned into vapor area below cooling coils on tank.
(b) Allow parts to be heated to the same temperature of the vapor. The heated vapor condenses on part to
be degreased because the part is relatively cool, thus dissolving oil and grease and carrying it away. When the part is heated to
the same temperature of the vapor. the cleaning action ceases.
(c) If further cleaning of the part is required, the part must be removed from tank and allowed to cool
before immersion again into vapor.
8.
SPECIAL INSPECTION REQUIREMENTS.
The maintenance of the gas turbine requires that inspection checks be made periodically. The inspection requirements and
limits throughout this manual are based on operation within specified limits. In addition to the regular inspections, there are
special inspections necessary when the gas turbine has operated outside of the specified limits, for example, off-schedule variable geometry operation, overspeed, or overtemperature. There may also be special inspections necessary if the gas turbine
has been exposed to abnormal conditions. These events include failures with significant damage and other abnormal exposure
such as an installation fire or mishap during transportation, handling, or storage. Some of the conditions to which an engine
may be exposed are:
a.
Shock loading, collision impact, exposure to explosion, handling or transportation mishap.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
b.
c.
separates.
Page 34
Structural overstress. mounting system overload to gas turbine interface (e.g .. earthquake. installation error).
Any equipment failure where parts are not contained within the gas turbine or where a major rotating component
d.
Sudden seizure or stoppage of the gas turbine rotor(s) or driven equipment rotors.
e.
Excess G-Ioading during operation in excess of packager manual limits.
f.
Significant inlet ingestion events (e.g .. foreign objects causing significant tlowpath damage. ice ingestion. inlet
system failure).
g.
Exposure to external fire, involving inlet system. exhaust system, base. enclosure. and equivalent.
h.
Exposure to external fire in storage or transport.
1.
Internal fire.
J.
Thermal quench by water or other agent. local overheating by fuel or steam system failure.
k.
Exposure to corrosive chemicals. fire-fighting agents. salt water. or sewage.
These events are highly variable and the exposure and associated damage which a gas turbine experiences is unpredictable.
This prevents establishing a single. all-inclusive inspection and repair procedure. Depending upon the circumstances of the
event. instances of localized, limited damage can often be dispositioned by normal channels.
For abnormal events such as the 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 or repair action to restore serviceability after a mishap. contact the
following for guidance:
GE Aircraft Engines
Marine & Industrial Customer service
Mail Drop S-155
I Neumann Way
Cincinnati, Ohio 452 I5-1988 USA
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 must be formally
reviewed for severity of operation beyond the normal working environment and dispostioned as to the necessity for a special
inspection workscope. The operator has the responsibility for the continued safe operating condition of the gas turbine. Since
used replacement parts may be available which have operated in abnormal events, the operator should verify that the service
histories of these parts are known and that. when applicable. the required special inspections and part disposition following
exposure to abnormal conditions have been completed and that the part is serviceable.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
007 00
31 May 2002
Page 35/36
Similarly, many components or assemblies from aircraft engines which have experienced previous flight service are not usable
in LM engines. In addition. gas turbine components which have experienced an extremely high number of start/stop cycles. or
partial cycles. such as in commercial marine service. may not be usable. Specifically, use of used-serviceable flight or highcycle engine parts in the following categories should be evaluated prior to use:
I.
Rotating components.
2.
Stator cases and stator vanes.
3.
Frame assemblies.
4.
Main shaft bearings.
Prior to use of other components, contact Marine and Industrial Engines Customer Service about usability.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
008 00
GEK 99441
Page 1 of 4
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
PREVENTIVE MAINTENANCE
PERIODIC INSPECTIONS AND MAINTENANCE
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................ .
Introduction ........................................................................ .
Periodic Inspections and Maintenance (Industrial Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Inspections and Maintenance (Marine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Equipment .................................................................. .
3
2
1. INTRODUCTION. This work package provides instructions for periodic inspections and maintenance tasks to be done
on a regular schedule. based on calendar time. Preventive maintenance consists of scheduled inspections, compressor cleaning
(water wash), servicing. calibration, troubleshooting, and adjustment of an installed gas turbine. The detailed procedures are
contained in reference work packages given in table I for the Marine gas turbine and table 2 for the Industrial gas turbine.
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
None
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
008 00
GEK 99441
31 May 2002
Page2
4. PERIODIC INSPECTIONS AND MAINTENANCE (MARINE ONLY). Refer to table I for periodic inspections
and maintenance frequency.
TABLE 1.
PERIODIC INSPECTIONS AND MAINTENANCE (MARINE ONLY)
Maintenance Item
Monthly
Engine
Change
100
Operating
Hours
6
Months
Interval
12
Month
Interval
Reference
Work
Package
Gas Turbine Inlet Inspection
X
009 00
Borescope Inspection
X
01000
Gas Turbine Exhaust Inspection
X
011 00
Variable Stator Vanes (VSV) System
Inspection and Rigging
X
012 00
Chip Detectors and Drain Plug Inspection
013 00
X
014 00
Preservation of Installed Gas Turbines
(As Required)
Spectrometric Oil Analysis Program (SOAP)
X
015 00
Gas Turbine External Inspection
X
01600
017 00
Compressor Cleaning (Water Wash)
(As Required)
Ignition System Test
X
018 00
Lubrication System Servicing
X
019 00
Fuel System Servicing (As Required)
Velocity Pickup Calibration
02000
X
Accelerometer Calibration
X
X
Note I
X
Note I
Note I - Send pickups to laboratory for shake test to verify output accuracy.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
008 00
GEK 99441
Page 3/4
31 May 2002
5. PERIODIC INSPECTIONS AND MAINTENANCE (INDUSTRIAL ONLY). Refer to table 2 for periodic inspections and maintenance frequency.
TABLE 2.
PERIODIC INSPECTIONS AND MAINTENANCE (INDUSTRIAL ONLY)
Six Months
Interval
Reference
Work
Package
Gas Turbine Inlet Inspection
X
009 00
Borescope Inspection
X
01000
Gas Turbine Exhaust Inspection
X
011 00
Variable Stator Vanes (VSV) System
Inspection and Rigging
X
012 00
Maintenance Item
Chip Detectors and Drain Plug Inspection
Three Months
Interval
013 00
X
014 00
Preservation of Installed Gas Turbines
(As Required)
X
Spectrometric Oil Analysis Program (SOAP)
Gas Turbine External Inspection
015 00
01600
X
017 00
Compressor Cleaning (Water Wash)
(As Required)
Ignition System Test
X
018 00
Lubrication System Servicing
X
019 00
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
009 00
GEK 99441
Page 1 of 6
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
GAS TURBINE INLET INSPECTION
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Consumable Materials ................................................................
Inspection of Gas Turbine Inlet. ........................................................
Introduction ........................................................................
Support Equipment ..................................................................
.
.
.
.
I
2
1. INTRODUCTION. This work package provides instructions for inspecting the gas turbine inlet area. Only those
checks critical to gas turbine operation are denoted in this work package.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
2C91IIIGOI
Borescope Kit
Bright Light
Mirror. Inspection
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
009 00
31 May 2002
Page2
Consumable Materials
4.
Description
Manufacturer
Brush, Soft-Bristle
Local Purchase
Gloves. Thermally Insulated
Local Purchase
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
Solvent. Dry Cleaning (Stoddard Solvent) P-D-680
Local Purchase
INSPECTION OF GAS TIJRBINE INLET.
a.
Before entering the gas turbine area to inspect the gas turbine inlet (see figure I). do the following:
(I)
Shut down the gas turbine.
(2)
Deactivate the fire extinguishing system.
I WARNING I
Handling Hot Parts
•
•
•
When handling hot parts, wear approved gloves.
Handling of hot parts with bare hands may cause reddening and blistering of skin, or third-degree bums.
If skin is burned. immerse contacted area in cold
water for I 0 minutes. If pain or blistering persists.
immediately get medical attention.
(3) Allow the gas generator to cool to room temperature. (Avoid contact with hot parts: wear thermally insulated gloves, if necessary.)
(4) Tag electrical switches "Out-Of-Service" to preclude inadvertent activation. Tag the gas turbine operating
controls "Do Not Operate" to prevent starting during a desired shutdown condition.
b.
Unlatch and lower. or remove. the lower half of inlet plenum (4). Verify that the inlet plenum drain port (3) is
unobstructed and open.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
009 00
GEK 99441
Page3
31 May 2002
7
\3
VIEW FORWARD LOOKING AFT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Inlet Screen
Borescope Path
Inlet Plenum Drain Port
Inlet Plenum (Lower Half)
Inlet Housing-to-Gas Turbine Seal
Compressor Inlet
Inlet Plenum (Upper Half)
Inlet Duct-to-Plenum Seal
Inlet Duct
CIT Sensor
Shielded Capillary Tube
Inlet Housing
c
OOOLM5-058200
Figure I.
Gas Turbine Inlet
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
009 00
Page4
31 May 2002
CAUTION
•
•
c.
The CIT sensor (10) is connected to the VG control
assembly by a shielded capillary tube ( 11 ). The sensor, tube, and brazed connections are fragile and may
be damaged or destroyed by mishandling.
Care must be taken when removing the sensor to
avoid bending or puncturing the sensor or tube resulting in loss of critical control functions.
Remove the sensor (I 0) from the upper half inlet plenum (7) as follows:
(I)
Unfasten any clamps between the tube ( 11) and the sensor (I 0) to allow free movement of the tube.
(2)
Remove lock wire and bolts securing sensor (I 0) to inlet plenum (7). Carefully remove sensor.
(3)
Inspect sensor (I 0) for evidence of impact damage or cracking.
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
(4)
contaminants.
(5)
32
Using a soft-bristle brush soaked with dry cleaning solvent, clean the sensor (10) to remove any dirt or
Inspect seal or gasket between sensor mounting plate and inlet plenum flange. Replace if damaged.
d.
Raise and latch the inlet duct (9).
e.
Remove the upper half of the inlet plenum (7) and do the following:
(I) Inspect the upper and lower halves of the inlet plenums (7. 4) and the inlet screen (I) for cleanliness. corrosion. loose or missing fasteners. cracked welds or damage. Use a bright light and inspection mirror, as necessary. to inspect
inlet screen (I).
(2)
Verify that the inlet duct-to-plenum seal (8) and the inlet housing-to-gas turbine seal (5) are in place and
intact.
f.
If any damage. looseness. or penetration of the inlet screen (I) is noted. do the following:
(I)
Remove four bolts and remove inlet screen (I).
(2) Using instructions in WP 010 00. borescope-inspect compressor inlet (6) through inlet housing (12).
(Note borescope path (2).)
(3)
Reinstall inlet screen (I). Using four bolts. secure inlet screen.
g.
Reinstall the lower half of the inlet plenum (4) and. if disconnected. reconnect the drain tube to drain port (3 ).
h.
Reinstall the upper half of the inlet plenum (7) by placing inlet plenum in position on seal.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
009 00
GEK 99441
31 May 2002
Page 5/6
1.
Unlatch and lower the inlet duct (9) onto the upper half of the inlet plenum (7). Install and tighten tlange bolts.
J.
Reinstall the sensor (I 0). tube ( 11 ). and clamps as follows:
CAUTION
•
•
(I)
The sensor (I 0) is connected to the VG control assembly by tube ( 11 ). The sensor. tube. and brazed connections are fragile and may be damaged or destroyed
by mishandling.
Care must be taken when installing the sensor to avoid
bending or puncturing the sensor or tube resulting in
loss of critical control functions.
Using bolts. secure sensor (I 0) to the upper half of the inlet plenum (7).
(2) Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire the bolts that secure sensor (I 0), using the
double-strand method (WP 007 00).
(3)
Fasten clamps between the tube ( 11) and the sensor (I 0).
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 1 of 54
31 May 2002
LMSOO GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
BORESCOPE INSPECTION
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Borescope Inspection
Combustion Liner. Fuel Injectors. and Stage I Turbine Nozzle .............................
Compressor Casing. Inlet Guide Vanes. Compressor Rotor Blades, Variable Vanes,
and Stationary Vanes ............................................................
Stage I High-Pressure Turbine (HPT) Rotor Blades. Using Igniter Ports S 18 and S23 ...........
Stages I and 2 High-Pressure Turbine (HPT) Rotor Blades, Using HPT Casing Port S49 .........
Stages 3 Through 5 Low-Pressure Turbine (LPT) Rotor Blades .............................
Consumable Materials ................................................................
General Instructions .................................................................
Introduction ........................................................................
Post Borescope Inspection Procedures ...................................................
Setup of Borescope Kit 2C91111 GO I ....................................................
Support Equipment ..................................................................
.
27
.
.
.
.
.
.
.
.
.
.
11
39
42
47
2
2
I
53
9
1. INTRODUCTION. This work package provides instructions to borescope-inspect internal areas of the assembled gas
turbine.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
2C91071GOI
Adapter. Igniter Port Borescope
2C91111GOI
Borescope Kit
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
Page2
31 May 2002
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
AlcohoL Isopropyl (IT-I-735)
Local Purchase
Beeswax
Local Purchase
Cloth, Lint-Free
Local Purchase
Compound, Magnesium Hydroxide
(U nflavored Milk of Magnesia)
Local Purchase
Gloves, Thermally Insulated
Local Purchase
Oil, Penetrating (VV-P-216)
Local Purchase
Lockwire. 0.032 inch (0.81 mm) diameter
Local Purchase
GENERAL INSTRUCTIONS.
a.
Only approved personnel is allowed to borescope-inspect the gas turbine. Incorrect inspection can cause gas turbine removal that is not necessary.
b. Borescope inspection procedures are provided to determine the conditions that can decrease the life of a part or
cause the gas turbine performance to become unsatisfactory. These borescope inspection procedures allow the operator to
inspect specified internal parts of an assembled gas turbine.
c.
The most important functions of borescope inspections are to:
•
•
•
•
d.
Monitor the compressor for foreign object damage (FOD)
Monitor the hot-section parts for uneven temperature distribution
Look for possible indications of high temperature stress
Monitor sensitive areas of the gas turbine.
Borescope inspection can help to decrease the number of times that:
•
•
•
The gas turbine is removed
Maintenance is done that was not scheduled
Teardown inspections are done.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page3
31 May 2002
NOTE
Borescope inspections are not as complete as periodic teardown inspections.
e.
To be sure that the complete stage (all blades) has been visually inspected, use the locking screw as a reference
mark. This will make sure that a full 360° turn of the compressor rotor has been inspected. (Refer to figure I for a typical
view of the stages 3 through 14 locking screw.) The cranking pad found between the fuel pump pad and the lube pump pad on
the accessory drive gearbox assembly can be used to rotate the compressor rotor 360°.
f.
The borescope ports that are available on the gas turbine for the borescope inspections have different
dimensions.
g.
The length of the borescope probe must be a minimum of I 0.5 inches (267 mm).
h. There are a number of borescope ports located on the gas turbine (see figure 2) which can be used to inspect the
internal parts of the gas turbine. Also, refer to table I for details of what can be viewed from designated borescope ports.
TABLE 1.
Port
Designation
(Refer to
Figure 2)
BORESCOPE PORT LOCATIONS
Position
(Aft Looking
Location
Forward)
View
Sl7
I o'clock
Combustion Chamber Frame
Fuel Injector
Sl8
2 o'clock
Igniter Port
Stage I Turbine Nozzle, Stage I
HPT Blades, and Stage I HPT
Shrouds
Sl8
2 o'clock
Igniter Port
Stage I Turbine Nozzle, and
Combustion Liner Inner and Outer
Shells
Sl8
2 o'clock
Igniter Port
Combustion Liner Swirler
S20
5 o'clock
Combustion Chamber Frame
Fuel Injector
S22
8 o'clock
Combustion Chamber Frame
Fuel Injector
S23
10 o'clock
Igniter Port
Combustion Liner Swirler and Fuel
Injector
S23
10 o'clock
Igniter Port
Stage I Turbine Nozzle
S23
10 o'clock
Igniter Port
Stage I HPT Blade Tip and Stage I
HPT Shrouds
S23
10 o'clock
Igniter Port
Stage I Turbine Nozzle Trailing
Edge and Stage I HPT Blades
S33
2 o'clock
Compressor Casing (IGV)
IGV Trailing Edge and Stage I
Blade Leading Edge
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 4
TABLE 1.
BORESCOPE PORT LOCATIONS (Cont)
Port
Designation
(Refer to
Figure 2)
Position
(Aft Looking
Forward)
S33
2 o'clock
Compressor Casing (IGV)
Stage I Blade Leading Edge and
Stage I Vanes
S33
2 o'clock
Compressor Casing (IGV)
IGV Trailing Edge and Stage I
Blade Leading Edge
S34
2 o'clock
Compressor Casing
(Stage 2)
Stage 2 Vane Leading Edge and
Stage 2 Blade Trailing Edge
S34
2 o'clock
Compressor Casing
(Stage 2)
Stage 2 Vane Trailing Edge and
Stage 3 Blade Leading Edge
S34
2 o'clock
Compressor Casing
(Stage 2)
Stage I Vane Trailing Edge. Stage 2
Blade Leading Edge, and Stage 2
Blade Trailing Edge
S34
2 o'clock
Compressor Casing
(Stage 2)
Stage 2 Vane Leading Edge and
Stage 2 Blade Trailing Edge
S35
2 o'clock
Compressor Casing
(Stage 6)
Stage 6 Vane Leading Edge and
Stage 6 Blade Trailing Edge
S35
2 o'clock
Compressor Casing
(Stage 6)
Stage 7 Vane Leading Edge. Stage 7
Blade Leading Edge. and Stage 7
Blade Trailing Edge
S36
12 o'clock
Compressor Casing
(Stage 12)
Not accessible through heat shield
S37
2 o'clock
Compressor Casing
(Stage 8)
Stage 8 Blade Trailing Edge and
Stage 8 Vane Leading Edge
S37
2 o'clock
Compressor Casing
(Stage 8)
Stage 9 Blade Leading Edge
S38
!I o'clock
Compressor Casing
(Stage 2)
Stage I Vanes and Stage 2 Blades
S38
11 o'clock
Compressor Casing
(Stage 2)
Stage 2 Vanes
S38
11 o'clock
Compressor Casing
(Stage 2)
Stage 2 Blades. Stage 2 Vanes. and
Stage 3 Blades
S39
11 o'clock
Compressor Casing (IGV)
Stage I Blade Leading Edge and
IGV Trailing Edge
S39
11 o'clock
Compressor Casing (IGV)
Stage I Blades and Stage I Vanes
Location
View
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 5
TABLE 1.
BORESCOPE PORT LOCATIONS (Cant)
Port
Designation
(Refer to
Figure 2)
Position
(Aft Looking
Forward)
S40
10 o'clock
Compressor Casing
(Stage 12)
Stage 12 Blades
S40
10 o'clock
Compressor Casing
(Stage 12)
Stage 12 Vanes. Stage 13 Blades.
and Stage 13 Vanes
S40
10 o'clock
Compressor Casing
(Stage 12)
Stage 13 Vanes. Stage 13 Blades.
and Stage 14 Blades
S41
10 o'clock
Compressor Casing
(Stage 10)
Stage I 0 Vanes and Stage 11
Blades
S41
10 o'clock
Compressor Casing
(Stage 10)
Stage 11 Vanes and Stage 11
Blades
S45
2:30 o ·clock
Compressor Casing
(Stage 3)
Stage 3 Blade Trailing Edge and
Stage 4 Blade Leading Edge
S47
9:30 o'clock
Compressor Casing
(Stage 7)
Stage 7 Blade Trailing Edge and
Stage 8 Blade Leading Edge
S48
1:30o'clock
Compressor Casing
(Stage 9)
Stage 9 Blade Trailing Edge and
Stage I 0 Blade Leading Edge
S49
4:30 o'clock
HPT Casing
(Stage 2)
Stage I Blade Trailing Edge and
Stage 2 Blade Leading Edge
sso
4:30 o'clock
LPTCasing
(Stage 4)
Stage 3 Blade Trailing Edge and
Stage 4 Blade Leading Edge
SS!
4:30 o'clock
LPT Casing
(StageS)
Stage 4 Blade Trailing Edge and
Stage 5 Blade Leading Edge
View
Location
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page6
31 May 2002
1201 056-00-A2A
Figure L
View of Locking Screw on Stages 3 Through 14 (Typical)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page7
523
540
LEFT SIDE VIEW
517
536
549
RIGHT SIDE VIEW
c
OOOLMS-060700
Figure 2.
Location of Borescope Ports (Sheet I of 2)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 8
FORWARD FLANGE
COMPRESSOR CASING TOP HALF - TYPICAL LAYOUT
\0
.....
z
.....
0
-.:
n
r-
....J
::><:
Q..
Cl)
Cll
"'0
:0.:
r-
.....
g
-t
r-
....J
?
z
..,0
I"T1
1201057-00-A2A
Figure 2.
Location of Borescope Ports (Sheet 2 of 2)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
GEK 99441
31 May 2002
1.
Page 9
A complete inspection using the borescope kit allows the operator to inspect the following:
(I) The compressor inlet guide vanes (IGV's) and the stage I compressor rotor blades and vanes through borescope ports S33 and S39 (on compressor casing).
(2) The stages 2 through 10 compressor rotor blades and vanes through borescope ports S34. S35. S37. S38.
S41. S45. S47, and S48 (on compressor casing).
(3) The stage 11 compressor rotor blades and vanes with visible portions of stage I 0 vanes through bore scope
port S41 (on compressor casing).
(4) The stages 12, 13, and 14 compressor rotor blades and stages 12 and 13 vanes through bore scope ports S36
and S40 (on compressor casing).
NOTE
During normal hot section-parts inspection. if a piece of a
part (not clearly visible) is damaged. inspection ports S 17.
S 18. S20. S22, or S23 on the combustion chamber frame
can be used to do a more complete inspection of the part.
(5) The combustion liner dome. inner shell, outer shell. fuel injectors. and swirlers through borescope ports
S 18 and S23 (on the combustion chamber frame through the igniter port).
(6) The stage I turbine nozzle partitions and the stage I turbine rotor blades through borescope ports S 18 and
S23 (on the combustion chamber frame through the igniter port).
5.
(7)
The stage I and stage 2 HfYT rotor blades through borescope port S49 (on the HfYT casing).
(8)
The stages 3 through 5 LfYT rotor blades through bore scope ports S50 and SS! (on the LfYT casing).
SETUP OF BORESCOPE KIT 2C91111G01.
a.
Remove the protective cover from the light source set (see figure 3).
b.
Turn the light source ON/OFF switch to the OFF position and turn the brightness switch to L (low).
c.
Connect the light source to a 115 volt. 60Hz power source.
Isopropyl Alcohol, TT-1-735
11
CAUTION
Borescopes are delicate instruments. Handle all parts carefully and return them to their case when not in use.
d.
Using a lint-free cloth soaked with isopropyl alcohol. clean the eyepiece. the lens. and each of the two ends of
the flexible fiber optic cable.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
Page 10
31 May 2002
LIGHT SOORCE
SET
1201058-00-02
Figure 3.
Borescope Kit 2C91111 GO I
NOTE
•
•
Inspection of combustion section with rigid borescope
is accomplished in the same way at each inspection
port
The flexible borescope is used for inspection through
igniter plug ports and inspection of gas turbine inlet
e.
Connect one end of the flexible fiber optic cable to the light source and connect the other end to the applicable
borescope probe.
f
Before entering the gas turbine area to borescope-inspect the gas turbine, do the following:
(I)
Shut down the gas turbine.
(2)
Deactivate the fire extinguishing system.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page_
010 00
GEK 99441
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31 May 2002
I WARNING I
Handling Hot Parts
•
•
•
When handling hot parts, wear approved gloves.
Handling of hot parts with bare hands may cause reddening and blistering of skin. or third-degree hums.
If skin is burned, immerse contacted area in cold
water for I 0 minutes. If pain or blistering persists.
immediately get medical attention.
(3)
Allow the gas generator to cool to room temperature. (Avoid contact with hot parts: wear thermally insulated gloves, if necessary.)
(4) Tag electrical switches "Out-Of-Service" to preclude inadvertent activation. Tag the gas turbine operating
controls "Do Not Operate" to prevent starting during a desired shutdown condition.
(5)
Remove customer equipment that prevents access to borescope inspection ports.
6. BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR ROTOR
BLADES, VARIABLE VANES, AND STATIONARY VANES.
I CAUTION I
Be careful and do not let unwanted objects or material go
into the opening in the accessory drive gearbox (AGB).
Damage to the AGB can occur.
a.
Remove the snapring and the cranking pad cover (found between the fuel control and the lube and scavenge
pump) on the aft side of the accessory drive gearbox.
b.
Connect a :VS-inch drive extension to a ratchet wrench. then put the extension into the 3/8-inch square hole in
the gearshaft.
c.
Slowly turn the ratchet wrench in a clockwise or a counterclockwise direction to turn the rotor.
d.
Borescope-inspect the right side and the left side of compressor as follows:
NOTE
The procedure that follows is applicable to the right side and
the left side of the compressor. The differences between the
two are specified.
(I) For the right side of the compressor. remove the bore scope port plugs S33, S34, S35. S37. S45, and S48
that are found on the compressor casing (sec figure 2).
(2) For the left side of the compressor, remove the borescope port plugs S38, S39, S40, S41, and S4 7 that are
found on the compressor casing.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 12
CAUTION
•
•
Only approved personnel is allowed to horescopeinspect the gas turbine. Incorrect inspection can cause
gas turbine removal that is not necessary.
Be sure the inlet turbine temperature is less than
l22°F (50°C) before you start the horescope procedure. Damage to the horescope can occur if the temperature is more than I22°F (50°C).
NOTE
It will he easier to see the components to he inspected if you
use a rigid horescope that is 0.236 inch (6.0 mm) or less
diameter, and will view at a right angle.
(3)
Turn the light source ON/OFF switch to the ON position and turn the brightness switch from the L to the
H position.
CAUTION
Be very careful and do not let the horescope probe touch the
rotor or the rotor blades when you put probe into the gas turbine. Damage to the rotor and the rotor blades can easily
occur.
(4) Insert the horescope probe approximately 0.750 inch (19.05 mm) into the horescope port on the
compressor casing.
(5)
Adjust the depth of the horescope pro he and rotate probe until you can see the compressor blade.
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
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GEK 99441
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31 May 2002
CAUTION
•
•
Before you turn the rotor. be sure the borescope probe
will not touch the internal parts of the gas turbine.
Damage to the internal parts of the gas turbine and to
the borescope probe can occur.
Count the rotor blades as you look at them when you
inspect the stages I and 2 compressor rotor blades.
Stage I has 30 blades and stage 2 has 38 blades.
These stages do not have locking screws and an incorrect inspection can cause gas turbine removal that is
not necessary.
NOTE
•
•
•
The leading edge and the trailing edge of the rotor
blade can be seen from the same angle.
The fuel pump will make a loud ratcheting noise
when you turn the ratchet wrench.
One complete turn of the cranking pad equals 2-1/2
complete turns of the compressor rotor.
(6) Slowly turn the ratchet wrench in a clockwise or a counterclockwise direction to turn the cranking pad. and
inspect the compressor casing. the inlet guide vanes, the rotor spools, the rotor blades. the variable vanes, and the stationary
vanes. Refer to table 2 for inspection limits and corrective action.
(7) Turn the brightness switch on the light source from the H to the L position and put the ON/OFF switch to
the OFF position.
(8)
Carefully remove the borescope probe from the borescope port.
(9)
Using procedures in steps (I) through (8), do a borescope inspection through other borescope ports.
NOTE
A thin coat of beeswax can be applied to the borescope plug
scaling washer to help hold the washer in the correct position during installation.
(I 0) Lubricate the external threads of the removed borescope plugs with magnesium hydroxide compound
(untlavored milk of magnesia). Let compound dry before installing plugs.
( 11) For the right side of the compressor. install the borescope port plugs S34, S37, S45, and S48. Torque the
plugs to 70-80 lb in. (7.9-9.0 N·m).
( 12) For the right side of the compressor, install the borescope port plugs S33 and S35. Torque the plugs to
90-100 lb in. (I 0.2-11.3 N·m).
( 13) For the left side of the compressor. install the borescope port plugs S38, S40. and S47. Torque the plugs to
70-80 lb in. (7.9-9.0 N·m).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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31 May 2002
( 14) For the left side of the compressor. install the borescope port plugs S39 and S41. Torque the plugs to
90-100 lb in. (I 0.2-11.3 N·m).
( 15) Using 0.032 inch (0.81 mm) diameter lock wire. lock-wire borescope plugs using the double-strand method
(WP 007 00).
TABLE 2.
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES
Inspect
a.
Usable Limits
Corrective Action
Permitted if the gas turbine performance and vibration levels are satisfactory, and there is no unserviceable
FOD.
If there is unserviceable FOD. replace
gas turbine.
Permitted if:
If the defect is more than the usable
limits, replace gas turbine.
Visible areas of the compressor
casing for:
(I) Abradable coating that has
come off.
(2) Rub marks because the blades
have rubbed the compressor
casing.
(a) There is no high metal.
(b) The external area of the compressor casing is not discolored
because of heat.
(c) The gas turbine performance and
vibration levels are satisfactory.
(d) There is no unserviceable FOD.
b.
Inlet guide vanes (see figure 4)
for:
(I) Cracks in the parent metal.
None permitted.
Replace gas turbine.
(2) Nicks. dents, and scratches in
the trailing edge.
Permitted if:
If the defect is more than the usable
limit replace gas turbine.
(a) The depth of each defect is less
than 0.060 inch ( 1.52 mm).
(b) There is no high metal.
(c) The gas turbine performance is
satisfactory.
(3) Surface areas that are rough.
Permitted if the gas turbine performance is satisfactory.
No action necessary.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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31 May 2002
TABLE 2.
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES (Cont)
Usable Limits
Corrective Action
(I) Abradable coating that is
loose or has come off because
of rubs. erosion, or FOD.
Permitted if the gas turbine performance and vibration levels are satisfactory. and there is no unserviceable
FOD.
If there is unserviceable FOD. replace
gas turbine.
(2) Adbradable coating that is
Permitted if the gas turbine performance and vibration levels are satisfactory. and there is no unserviceable
FOD.
If there is unserviceable FOD. replace
gas turbine.
Permitted if the gas turbine performance is satisfactory.
If the rotor spools are frequently dirty.
increase the number of times the gas
turbine is water washed.
None permitted.
Replace gas turbine.
Inspect
c.
Visible areas of the rotor spools
for:
loose or has come off because
of delamination.
(3) Contamination and
discoloration (apparent oil or
dirt).
d.
Rotor blades (see figure 5) for:
(I) Cracks or torn metal.
NOTE
•
•
Critical areas are defined as the inner 1/3 of the blade, from the platform outward. Also. the fillet at the root of the blade.
Noncritical areas are defined as the visible remaining area of the blade.
(2) Critical areas for nicks, dents,
and bends.
None permitted.
Replace gas turbine.
(3) Noncritical areas for nicks.
dents. and bends.
Permitted if the depth of each defect is
less than 0.010 inch (0.25 mm), and
the gas turbine performance is satisfactory.
If the defect is more than the usable
limit, replace gas turbine.
(4) Platform for nicks, pits. and
Permitted if:
If the defect is more than the usable
limit, replace gas turbine.
scratches.
(a) The depth of each defect is less
than 0.015 inch (0.38 mm).
(b) There is no high metal.
(c) The gas turbine performance is
satisfactory.
(5) Corners of the locking blades
for damage.
Not permitted.
Replace gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
TABLE 2.
Page 16
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES (Cant)
Inspect
(6) Platform edges for nicks and
dents.
Usable Limits
Corrective Action
Permitted if:
If the defect is more than the usable
limit, replace gas turbine.
(a) The depth of each defect is less
than 0.063 inch ( 1.60 mm).
(b) 75 percent of each edge is not
damaged.
(c) There is no high metal.
(d) The gas turbine performance is
satisfactory.
because of erosion.
Permitted if the gas turbine performance is satisfactory.
If the gas turbine performance is not
satisfactory, replace gas turbine.
(8) Jagged trailing edge tip
because of erosion.
Permitted if the gas turbine performance is satisfactory.
If the gas turbine performance is not
satisfactory. replace gas turbine.
(a) Burrs because of rubs.
Permitted if the gas turbine performance is satisfactory.
If the gas turbine performance is not
satisfactory, replace gas turbine.
(b) Curling.
Permitted if:
If the defect is more than the usable
limit. replace gas turbine.
(7) Surface areas that are rough
(9) Blade tips for:
e.
I
Defects are less than 0.020 inch
(0.51 mm) from the original contour on all blades.
2
Defects are less than 0.063 inch
( 1.60 mm) from the original contour on a maximum of 10 percent
of the blades in a stage.
3
The gas turbine performance is
satisfactory.
Variable vanes for:
(I) Cracks or torn metal.
None permitted.
Replace gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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31 May 2002
TABLE 2.
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES (Cont)
Inspect
Usable Limits
Corrective Action
NOTE
•
•
Critical areas are defined as the inner 1/3 of the vane, from the platform outward. Also, the fillet at the root of the vane airfoil.
Noncritical areas arc defined as the visible remaining area of the vane.
(2) Critical areas for nicks, dents.
pits, and scratches.
Permitted if:
If the defect is more than the usable
limit. replace gas turbine.
(a) The depth of each defect is less
than 0.010 inch (0.25 mm) for
stages I and 2.
(b) The depth of each defect is less
than 0.005 inch (0.13 mm) for
stages 3. 4. and 5.
(c) The gas turbine performance is
satisfactory.
(3) Noncritical areas for:
(a) Nicks.
Permitted if:
I
The depth of each defect is less
than 0.031 inch (0.79 mm).
2
There is no high metal.
3
The gas turbine performance is
satisfactory.
If the defect is more than the usable
limit, replace gas turbine.
Permitted if the depth of each defect is
less than 0.031 inch (0.79 mm). and
the gas turbine performance is satisfactory.
If the defect is more than the usable
limit, replace gas turbine.
(a) Surface areas that are
rough because of erosion.
Permitted if the gas turbine performance is satisfactory.
If the gas turbine performance is not
satisfactory, replace gas turbine.
(b) Jagged trailing edges
because of erosion.
Permitted if there is no curled material
and the gas turbine performance is satisfactory.
If there is curled material. replace gas
turbine.
(b) Dents and bends in the
leading and trailing
edges.
(4) Airfoil section for:
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
TABLE 2.
Page 18
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES (Cant)
Inspect
(5) Leading edge of the platform
for under cut because of
erosion.
Usable Limits
Corrective Action
Permitted if:
If the defect is more than the usable
limit. replace gas turbine.
(a) The depth of each defect is less
than 0.040 inch ( 1.02 mm) for
stages I and 2.
(b) The depth of each defect is less
than 0.020 inch (0.51 mm) for
stages 3. 4, and 5.
(c) The gas turbine performance is
satisfactory.
f.
Stationary vanes for:
(I) Cracks or torn metal.
Replace gas turbine.
None permitted.
NOTE
•
•
Critical areas are defined as the inner I /3 of the vane. from the platform outward. Also. the fillet at the root of the vane airfoil.
Noncritical areas are defined as the visible remaining area of the vane.
(2) Critical areas for nicks, pits.
dents. and scratches.
Permitted if the depth of each defect is
less than 0.005 inch (0.13 mm), and
the gas turbine performance is satisfactory.
If the defect is more than the usable
limit. replace gas turbine.
(3) Noncritical areas for nicks.
Permitted if:
If the defect is more than the usable
limit, replace gas turbine.
pits. dents, and scratches.
(a) The depth of each defect is less
than 0.031 inch (0.79 mm).
(b) There is no high metal.
(c) The gas turbine performance is
satisfactory.
(4) Vane platform for nicks. pits.
dents, and scratches.
Permitted if:
If the defect is more than the usable
limit. replace gas turbine.
(a) The depth of each defect is less
than 0.031 inch (0.79 mm).
(b) There is no high metal.
(c) The gas turbine performance is
satisfactory.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
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31 May 2002
TABLE 2.
BORESCOPE INSPECTION OF COMPRESSOR CASING, INLET GUIDE VANES, COMPRESSOR
ROTOR BLADES, VARIABLE VANES, AND STATIONARY VANES (Cont)
Usable Limits
Corrective Action
(a) Burrs because of rubs.
Permitted if the gas turbine performance is satisfactory.
Replace gas turbine.
(b) Curling.
Permitted if:
If the defect is more than the usable
limit. replace gas turbine.
Inspect
(5) Vane tips for:
I
Defects are less than 0.03 I inch
(0.79 mm) from the original contour on all vanes.
2
Defects are less than 0.050 inch
( 1.27 mm) from the original contour on a maximum of 10 percent
of the vanes in a stage.
3
The gas turbine performance is
satisfactory.
(6) Airfoil section for:
(a) Surface areas that are
rough because of erosion.
Permitted if the gas turbine performance is satisfactory.
Replace gas turbine.
(b) Jagged edges because of
erosiOn.
Permitted if there is no curled material
and the gas turbine performance is satisfactory.
If there is no curled material. replace
gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
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Page 20
31 May 2002
IGV
::---TRAILING EDGE
STAGE 1 BLADE
LEADING EDGE
IGV
TRAILING EDGE
STAGE 1 BLADE
LEADING EDGE
STAGE 1 BLADE
LEADING EDGE
IGV
TRAILING EDGE
1201 059-00·A2A
Figure 4.
Views of Inlet Guide Vanes
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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Page 21
STAGE 1 BLADE
LEADING EDGE
STAGE 1 VANES
STAGE 1 VANES
STAGE 1 BLADES
STAGE 1 VANES
STAGE 2 BLADES
1201 060·00·A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet I of 6)
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
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31 May 2002
STAGE 2 BLADE
TRAILING EDGE
STAGE 2 BLADE
LEADING EDGE
STAGE 2 VANES
STAGE 2 BLADE
TRAILING EDGE
1201061-00·A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet 2 of 6)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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31 May 2002
STAGE 2 VANE
LEADING EDGE
STAGE 2 VANES
STAGE 2 VANE
TRAILING EDGE
STAGE 3 BLADE
LEADING EDGE
1201062-00-A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet 3 of 6)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page24
STAGE 6 BLADE
TRAILING EDGE
STAGE 7 VANE
LEADING EDGE
STAGE 7 BLADE
LEADING EDGE
STAGE 8 BLADE
TRAILING EDGE
STAGE 8 VANE
LEADING EDGE
1201 063-00-A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet 4 of 6)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 25
STAGE 9 BLADE
LEADING EDGE
STAGE 11 BLADES
STAGE 11 VANES
1201064-00-A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet 5 of 6)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 26
STAGE 12 BLADES
STAGE 13 VANES
STAGE 13 BLADES
STAGE 12 VANES
STAGE 13 BLADES
STAGE 14 BLADES
STAGE 13 VANES
1201 065-00-A2A
Figure 5.
View of Compressor Rotor Blades and Vanes (Sheet 6 of 6)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
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31 May 2002
7. BORESCOPE INSPECTION OF COMBUSTION LINER, FUEL INJECTORS, AND STAGE 1 TURBINE
NOZZLE.
a.
ber frame.
Remove (WP 023 00) two igniter plugs from the 2 and I 0 o'clock positions (S 18 and S23) on combustion cham-
CAUTION
•
•
Only approved personnel is allowed to borescopeinspect the gas turbine. Incorrect inspection can cause
gas turbine removal that is not necessary.
Be sure the inlet turbine temperature is less than
I22°F (50°C) before you start the borescope procedure. Damage to the borescope can occur if the temperature is more than I22°F and (50°C).
NOTE
It will be easier to see the components to be inspected if you
use a rigid borescope 0.315 inch (8.00 mm) or 0.394 inch
(10.00 mm) diameter, and will view at a right angle. Different views can be seen, and a more complete inspection of
any area can be done if you use a flexible borescope
0.236 inch (6.0 mm) or less diameter.
b. Turn the light source ON/OFF switch to the ON position and turn the brightness switch from the L position to
the H position.
I CAUTION I
Be very careful and do not let the borescope probe touch the
internal parts of the gas turbine when you put probe into the
igniter port. Damage to the internal parts can occur.
NOTE
•
•
The compressor rotor and the high-pressure turbine
(HPT) rotor are not turned when you inspect the combustion liner and the stage I turbine nozzle.
If you think that a piece of a part (not clearly visible)
is damaged, inspection can be done through borescope port plugs S 17, S20, and S22 to do a more complete inspection of the part.
c.
Insert the borescope probe approximately 2 inches (51 mm) into the igniter port at the 2 o'clock position (S 18 ).
Turn the borescope probe until you can see a view that is forward. Adjust the depth and turn the borescope probe until you can
see the combustion liner swirlers as shown in figure 6.
d.
Turn the borescope probe clockwise and inspect all of the swirlers that you can see to make sure the end of the
fuel injector is in the center of the swirl er.
e.
Turn the borescope probe counterclockwise and inspect all of the swirlers that you can see to make sure the end
of the fuel injector is in the center of the swirler.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
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Page28
FUEL
INJECTOR
COMBUSTION LINER
SWIRLER
FUEL
INJECTOR
COMBUSTION LINER
SWIRLER
Figure 6.
1201 066-00-A2A
View of Combustion Liner Swirl er and Fuel Injector
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page29
31 May 2002
f.
Adjust the depth and turn the borescope probe until you can see the outer shell as shown in figure 7.
g.
Inspect all visible areas of the outer shell as follows:
(I)
Start at the swirler and turn the borescope probe (inspect the outer shell as you turn probe) until the stage I
turbine nozzle can be seen.
(2) Adjust the depth of the borescope probe after each pass. until all of the areas have been completely
inspected. Refer to table 3 for inspection limits and corrective action.
h. Adjust the depth of probe and slowly turn the borescope probe clockwise until you can see the inner shell as
shown in figure 7.
1.
Inspect all visible areas of the inner shell as follows:
(I)
Start at the swirler and turn the borescope probe (inspect the inner shell as you turn probe) until the stage I
turbine nozzle can be seen.
(2) Adjust the depth of the borescope probe after each pass. until all of the areas of the inner shell have been
completely inspected. Refer to table 3 for inspection limits and corrective action.
NOTE
The stage I turbine blade tips can be seen through the
stage I turbine nozzle.
j.
Slowly turn the borescope probe until you can see the stage I turbine nozzle as shown in figure 7. Refer to
table 4 for inspection limits and corrective action. Also, see figure 8 to view the turbine nozzle from different directions.
k.
Slowly turn the borescope probe in a counterclockwise direction (inspect the nozzle vanes as you turn probe)
until the outer shell can be seen.
I.
Slowly turn the borescope probe in a clockwise direction (inspect the nozzle vanes as you turn probe) until the
outer shell comes into view.
m. Turn the brightness switch on the light source from the H to the L position and turn the ON/OFF switch to the
OFF position.
n.
Carefully remove the borescope probe from the igniter port.
o.
Follow procedures in steps c through n for the igniter port at the I 0 o ·clock position (S23 ).
p.
If borescope port plugs S 17, S20. and S22 were removed, reinstall them as follows:
(I)
(2)
Install plugs in applicable borescope port. Torque plug to 180-200 lb in. (20.3-22.6 N·m).
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire borescope plugs using the double-strand method
(WP 007 00).
q. Do not install the igniter plugs until the stage I HPT rotor blades have been inspected as specified in
paragraph 8.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 30
COMBUSTION LINER
OUTER SHELL
STAGE 1 TURBINE
NOZZLE
COMBUSTION LINER
INNER SHELL
COMBUSTION LINER
OUTER SHELL
BAFFLE
COOLING LIP
COMBUSTION LINER
OUTER SHELL
STAGE 1 TURBINE
NOZZLE SEGMENT
LEADING EDGE
COMBUSTION LINER
INNER SHELL
Figure 7.
1201067 -OO-A2A
View of Combustion Liner Outer and Inner Shells. and Leading Edge of Stage I Nozzle Segments
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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Page 31
STAGE 1 HPT BLADE AS SEEN
THROUGH STAGE 1 lURBINE
NOZZLE USING A FLEXIBLE
BORESCOPE
STAGE 1 TURBINE
NOZZLE
CRACK IN LEADING EDGE
HITH RESULTING TRAIL
OF SOOT DISCOLORATION
STAGE 1 HPT BLADE
Figure 8_
1201068-00-A2A
View of Stage I Turbine Nozzle_ Stage I HPT Rotor Blade. and Stage I HPT Shrouds (Sheet I of 3)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page_
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31 May 2002
STAGE 1 HPT BLADE
STAGE
1
HPT
COOLING HOLE IN SHROUD
STAGE
STAGE 1 TIJRBINE
TRAILING EDGE
1
HPT BLADE
STAGE 1 HPT BLADE
TRAILING EDGE
COOLING HOLES
1201069-00-A2A
Figure 8.
View of Stage I Turbine Nozzle. Stage I HPT Rotor Blade. and Stage I HPT Shrouds (Sheet 2 of 3)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
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Page 33
31 May 2002
STAGE 1 TURBINE
NOZZLE
TRAILING EDGE
STAGE 1
HPT SHROUD
STAGE 1
HPT BLADE
STAGE 1
HPT BLADE TIP
STAGE 1 TURBINE
NOZZLE
STAGE 1
HPT SHROUD
1201070-00-A2A
Figure 8.
View of Stage I Turbine Nozzle. Stage I HPT Rotor Blade. and Stage I HPT Shrouds (Sheet 3 of 3)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 34
TABLE 3.
BORESCOPE INSPECTION OF COMBUSTION LINER
Usable Limits
Corrective Action
(a) Which run
circumferentially around
the shell.
Total circumferential length of a crack
not to exceed 3 inches (76 mm). Two
adjacent dilution holes (26) may be
connected by a crack if no other crack
has started from either connected hole
towards a third hole. Cumulative
length of all cracks in a shell band
must not exceed 12 inches (305 mm) if
no pattern is formed by any of the
cracks where a piece is in danger of
falling out.
Replace gas turbine.
(b) Other than
circumferential (may be
connected with cooling
lip cracks).
Any number, 1.5 inches (38 mm) long
if cracks are 0.375 inch (9.53 mm)
apart and no piece is in danger of falling out.
Replace gas turbine.
Any number, 0.031 inch (0.79 mm)
long and no closer than 1/2 inch
(13 mm).
Replace gas turbine.
Inspect
a.
Combustion liner outer and inner
shells (2, 3, figure 9) for:
( 1) Cracks in shell bands ( 1), not
including cooling lips (4 ):
(2) Cracks ih welds.
NOTE
The hot sides of the combustion liner are the ID of the outer shell (2) and the OD
of the inner shell (3 ).
(3) Distortion of cooling lips (4).
(Annular slots aft of each
band of aspirator holes on hot
side of shell.)
Gap between lip and the shell to be as
follows:
Replace gas turbine.
(a) Aft gap on the inner shell (3) no
less than 0.078 inch ( 1.98 mm).
(b) Aft gap on the outer shell (2) no
less than 0.094 inch (2.39 mm).
Replace gas turbine.
(c) All other gaps no less than
0.094 inch (2.39 mm).
Replace gas turbine.
(4) Dents.
Contour of defective area distorted no
more than 0.062 inch ( 1.57 mm) above
or below adjacent undistorted section.
Replace gas turbine.
(5) Local distortion due to high
temperature.
Contour of defective area to be more
than 0.188 inch (4.78 mm) above or
below adjacent undistorted contour.
Replace gas turbine.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 35
TABLE 3.
BORESCOPE INSPECTION OF COMBUSTION LINER (Cant)
Usable Limits
Corrective Action
(6) Burn holes in inner and outer
shells.
Ten per shell hand. if hole diameter
does not exceed 0.250 inch (6.35 mm)
and cracks extending from the defect
have been previously repair-welded.
Replace gas turbine.
(7) Burnout or erosion of cooling
Ten areas per lip if defect is no deeper
than 0.188 inch (4.78 mm) from the
original contour.
Replace gas turbine.
Any number, if no piece is in danger of
falling out.
Replace gas turbine.
Any amount. if defect does not extend
forward from hand trailing edge more
than 0.375 inch (9.53 mm) and the
edges of the defect are smooth and in
the normal contour of the hand.
Replace gas turbine.
(a) Radial.
Ariy number, any length.
No action necessary.
(h) Circumferential.
Any number. 0.750 inch ( 19.05 mm)
maximum length if cumulative length
per baffle does not exceed 1.5 inches
(38 mm).
Replace gas turbine.
(c) Connecting
circumferential and
radial cracks.
(I) A circumferential crack may connect two radial cracks if radial
cracks do not extend across entire
baffle from outer edge (sec
view B).
Replace gas turbine.
(2) A circumferential crack may
extend 1/2 the distance between
two radial cracks that extend
across the entire haftle from outer
edge to inner edge (see view B).
Replace gas turbine.
(2) Missing baffle material due to
cracking or fragmentation
(see view B).
None permitted.
Replace gas turbine.
(3) Burnout.
Permitted at corners and along edges.
if no more than 16 cooling holes in
dome ( 14) are visible: eight on top and
eight on bottom side of the haftle (see
view A).
Replace gas turbine.
Inspect
lips (4).
(8) Cracks in the cooling lips (4 ).
(May he connected with shell
cracks.)
b.
Outer hand (7) for burnout.
c.
Baffles ( 15) for:
(I) Cracks:
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 36
TABLE 3.
Usable Limits
Corrective Action
(4) Buckling.
Any amount, if baffle-to-dome gap is
not less than 0.031 inch (0.79 mm).
Replace gas turbine.
(5) Carbon buildup.
Any amount. with no fuel injector
obstruction.
No action necessary.
None permitted.
Replace gas turbine.
Inspect
d.
BORESCOPE INSPECTION OF COMBUSTION LINER (Cant)
Igniter ferrules (23) for:
(I) Cracks.
Penetrating Oil
(2) Seizure.
Ferrule must slide freely between
retainer and pad.
234
Try to move the ferrule until it is
released. Use penetrating oil to help
release seized parts. Otherwise,
replace gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 37
31 May 2002
28
6 13
28
12
10
SECTION Y-Y
VIEW A IN DIRECTION
OF ARROW X
MISSING MATERIAL
LEGEND.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Shell Band
Outer Shell
Inner Shell
Cooling Lip
Shell Cooling Hole
Outer Seal Support
Outer Band
Rub Strip (72 total)
Inner Flange
VIEW B IN DIRECTION
OF ARROW X
10.
11.
12.
13.
14.
15.
16.
17.
18.
Gang Channel Nut Assembly
Gang Channel Rivet
Aft Stop (24 total)
Outer Ring
Dome
Baffle
Outer Cowl
Inner Cowl
Secondary Vanes
CUTAWAY VIEW
AFT LOOKING FORWARD
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Bushing
Primary Vanes
Swirler Assembly
Cowl-to-Dome Held
Igniter Ferrule (2 total)
Fuel Primer Ferrule (2 total)
Locating Bracket
Dilution Hole
Cooling Gap
Stand-Off Pins (108 total)
1201071-00-A2A
Figure 9.
Inspection of Combustion Liner
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 38
TABLE 4.
BORESCOPE INSPECTION OF STAGE 1 TURBINE NOZZLE
Inspect
Usable Limits
Corrective Action
(a) Leading edge.
Any number. any length. extending
from the forward row of cooling holes
or between the leading edge cooling
holes to the concave side. Each crack
must not exceed 0.016 inch (0.41 mm)
in width and may connect up to six
leading edge cooling holes if there are
a minimum of two uncracked areas
preventing material from coming
loose. A 0.016 inch (0.41 mm) maximum width of complete penetration
through vane surface is permitted.
Replace gas turbine.
(b) Trailing edge.
Maximum crack length I inch
(25 mm). Cumulative length of all
cracks not to exceed 1.5 inch (38 mm).
Disregard cracks of 0.125 inch
(3.18 mm) long or less, if no piece is in
da.nger of falling out.
Replace gas turbine.
(c) Concave surface
(mid-chord).
Maximum crack length 1.250 inches
(31.75 mm). Cumulative length of all
cracks not to exceed 3.5 inches
(89 mm). Disregard cracks of
0.125 inch (3.18 mm) long or less, if
no piece is in danger of falling out.
Replace gas turbine.
(2) Holes or burnouts.
0.016 inch (0.41 mm) maximum width
of complete penetration through vane
surface is permitted.
Replace gas turbine.
(3) Nicks. pits. and scratches.
Any number. 0.016 inch (0.41 mm)
deep.
No action necessary.
(4) Plugged cooling air holes.
None permitted.
Replace gas turbine.
(5) Bent trailing edges.
Any amount. if gas turbine performance is satisfactory.
No action necessary.
(6) Hot gas corrosion
(sulfidation).
Any amount of discoloration or surface
roughness. if there is no blistering,
splitting. or separation (delamination)
of the airfoil surface.
No action necessary.
(7) Metal splatter.
Any amount. if cooling holes are not
plugged.
Replace gas turbine.
Vanes (see figure 8) for:
(I) Cracksin:
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 39
8. BORESCOPE INSPECTION OF STAGE 1 HIGH-PRESSURE TURBINE (HPT) ROTOR BLADES, USING
THE IGNITER PORTS S18 AND S23.
a.
If not previously removed. remove (WP 023 00) two igniter plugs from the 2 and I 0 o'clock positions
(S 18 and S23) on combustion chamber frame.
CAUTION
•
•
Only approved personnel is allowed to borescopeinspect the gas turbine. Incorrect inspection can cause
gas turbine removal that is not necessary.
Be sure the inlet turbine temperature is less than
122°F (50oC) before you start the borescope procedure. Damage to the borescope can occur if the temperature is more than l22°F (50°C).
NOTE
It will be easier to see the components to be inspected if you
use guide tube PN 17 A 1664 (part of 2C91111 GO I) with a
flexible borescope 0.236 inch (6.0 mm) diameter or less.
The length of the flexible borescope probe should be
40 inches (102 cm) minimum.
b. Turn the light source ON/OFF switch to the ON position and turn the brightness switch from the L position to
the H position.
NOTE
•
•
The igniter port borescope adapter 2C91071GOI (see
figure I 0) is used to support and secure the borescope
probe in igniter plug boss during the inspection of the
stage I HPT rotor blades.
The use of adapter 2C91071 GOI is optional.
c.
Thread holder (I, figure 10) into the 2 o'clock igniter port (S 18) by hand.
d.
Install stop (2) onto borescopc probe. Do not tighten knurled screw (3 ).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page40
31 May 2002
1.
2.
3.
4.
Holder
Stop
Knurl eel Screw
Tabs
1201072-00-A2A
Figure I 0.
Removal and Installation of Igniter Port Bore scope Adapter 2C91 071 GO I
I CAUTION I
•
•
Be sure the tabs (4) on stop (2) engage the antirotation
slots in holder (I ). Damage to the borescope probe
can occur if the stop rotates during the inspection.
Be very careful and do not let the borescope probe
touch the rotor or the rotor blades when turning the
rotor. Damage to gas turbine components and to borescope can occur.
e.
Put the borescope probe into the stop (2) and turn the borescope probe until you can see the aft view of gas turbine components. Adjust the depth and turn the borescope probe until the stage I HPT rotor blade tips can be seen between the
two nozzle vanes (see figure 8).
f.
Hand-tighten the knurled screw (3, figure 10) to hold the borescope probe in the desired position.
NOTE
One complete turn of the cranking pad equals 2-1/2 complete turns of the HPT rotor.
g.
Slowly turn the ratchet wrench in a clockwise or a counterclockwise direction to turn the cranking pad. and
inspect the HPT rotor blade tips. Refer to table 5 for inspection limits and corrective action.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 41
TABLE 5.
BORESCOPE INSPECTION OF STAGE 1 HPT ROTOR BLADES
Inspect
Usable Limits
Corrective Action
a.
Stage I rotor blades for cracks,
nicks, dents, and scratches in
coating or for other damage that
exposes parent metal.
No leading edge cracks permitted.
Trailing edge cracks permitted on
upper 1/4 of blade, up to 0.090 inch
(2.29 mm) long. Nicks. dents. and
scratches permitted in coating but not
into parent metal.
Replace gas turbine.
b.
Leading edge of rotor blades for
erosiOn.
0.010 inch (0.25 mm) maximum erosion, if gas turbine performance is satisfactory.
Replace gas turbine.
c.
Blade tips for rub grooves.
Any number. any width. if none exceed
0.020 inch (0.51 mm) depth, without
high metal.
Replace gas turbine.
d.
Plugged cooling holes.
Not permitted.
Replace gas turbine.
c.
Curled blade tip.
0.062 inch ( 1.57 mm) maximum on
leading and trailing edges.
Replace gas turbine.
f.
Hot gas corrosion (sulfidation).
Any amount of discoloration or surface
roughness, if there is no blistering.
splitting, or separation (delamination)
of the airfoil surface.
Replace gas turbine.
g.
Airfoil for buildup of metal
splatter.
Any amount. if gas turbine performance is satisfactory.
Replace gas turbine.
h.
Blade tip for burrs.
Any amount, if gas turbine performance is satisfactory.
Replace gas turbine.
h.
Adjust the depth of the borescope probe and turn the probe end up until the stage I blade leading edge can be
seen through the stage I nozzle (see figure I 0).
i.
Slowly turn the ratchet wrench and turn the rotor so that all the HPT blade leading edges can be inspected. Refer
to table 5 for inspection limits and corrective action.
j.
Turn the brightness switch on the light source from the H position to the L position and turn the ON/OFF switch
to the OFF position.
k.
Carefully remove the borescope probe from the igniter port.
I.
Remove adapter 2C91071 GO I from igniter port.
m.
Follow procedures in steps b through I for the igniter port at the I 0 o'clock position (S23 ).
n.
Reinstall (WP 023 00) the two igniter plugs.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 42
9. BORESCOPE INSPECTION OF STAGES 1 AND 2 HIGH-PRESSURE TIJRBINE (HPT) ROTOR BLADES,
USING HPT CASING PORT S49.
There are two types of borescope plug S49. the screwdriver slot bayonet type and the threaded type. Remove the bayonet
type per step a. and the threaded type per step b.
a.
Remove the bayonet type borescope plug S49 (figure 11. sheet I. detail A) as follows:
(I)
Insert a wide flat-blade screwdriver into the borescope plug.
I CAUTION:I
Be sure to press the borescope plug inward far enough so
that plug turns easily. If the plug is turned before pressing
plug inward sufficiently. damage to the plug or casing can
occur.
(2) Press the borescope plug inward approximately 0.10 inch (2.5 mm) until plug can be turned easily in the
counterclockwise direction.
(3) Push radially inward on the borescope plug approximately 0.20 inch (5.1 mm) and turn plug counterclockwise approximately 45 degree until slot in plug is approximately aligned with the unlocked position on the rear main mount.
See view B.
b.
(4)
Release pressure on the plug.
(5)
Remove the plug.
Remove the threaded type borescope plug S49 (figure 10, sheet 2. detail D) as follows:
(I)
Insert a 1/4-inch drive into the borescope plug socket.
I CAUTION I
Do not use excessive force when removing the borescope
plug or damage to the borescope plug and casing can occur.
(2)
Turn the plug counterclockwise until plug turns easily.
(3)
Remove the 1/4-inch drive from plug socket.
(4)
Remove the plug.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 43
31 May 2002
RIGHT SIDE
VIEW C
DETAIL A
S49
GROOVES
(2 PLACES
180• APART)
MAIN
MOUNT
BORES COPE
PLUG
HPT CASING BORESCOPE PORT
DETAIL B
SCREWDRIVER SLOT
BAYONET TYPE
BORESCOPE PLUG
LOCKED
UNLOCKED
1204050-00-A2A
Figure 11.
HPT Borescope Plug Removal and Installation (Sheet I of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
Page 44
31 May 2002
VIEW E
DETAIL D
S49
REAR
MAIN
MOUNT
BORESCOPE
PLUG
BORESCOPE
PLUG
THREADED TYPE BORESCOPE PLUG
Figure 11.
HPT Borescope Plug Removal and Installation (Sheet 2 of 2)
I CAUTION
•
•
1204051-00-02
J
Only approved personnel is allowed to borescopeinspect the gas turbine. Incorrect inspection can cause
gas turbine removal that is not necessary.
Be sure the inlet turbine temperature is less than
I22°F (50°C) before you start the borescope procedure. Damage to the borescope can occur if the temperature is more than I22°F (50°C).
NOTE
It will be easier to see the components to be inspected if you
use a rigid borescope 0.236 inch (6.0 mm) or less diameter,
and will view at a right angle.
c. Turn the light source ON/OFF switch to the ON position and turn the brightness switch from the L position to
the H position.
CAUTION
Be very careful and do not let the borescope probe touch the
rotor or the rotor blades when turning the rotor. Damage to
the gas turbine components and to borescope can occur.
d.
Insert the borescope probe through the borescope port on the HPT casing.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
e.
Page45
Adjust the depth of borescope probe and turn the borescope probe until you can see the rotor blades.
NOTE
•
•
The leading edge and the trailing edge of the rotor
blade can be seen from the same angle.
One complete turn of the cranking pad equals 2-1/2
complete turns of the HPT rotor.
f.
Slowly turn the ratchet wrench in a clockwise or a counterclockwise direction to turn the HPT rotor, and inspect
the rotor blades. Refer to table 6 for inspection limits and corrective action.
g.
Turn the brightness switch on the light source from the H position to the L position and turn the ON/OFF switch
to OFF.
TABLE 6.
BORESCOPE INSPECTION OF STAGES 1 AND 2 HPT ROTOR BLADES
Inspect
Usable Limits
Corrective Action
a.
Stages I and 2 rotor blades for
cracks, nicks, dents, and scratches
in coating or for other damage that
exposes parent metal.
No leading edge cracks permitted.
Trailing edge cracks permitted on
upper 1/4 of blade, up to 0.090 inch
(2.29 mm) long. Nicks, dents, and
scratches permitted in coating but not
into parent metal.
Replace gas turbine.
b.
Leading edge of rotor blades for
eroswn.
0.010 inch (0.25 mm) maximum erosion. if gas turbine performance is satis factory.
Replace gas turbine.
c.
Blade tips for rub grooves.
Any number, any width. if none exceed
0.020 inch (0.51 mm) depth. without
high metal.
Replace gas turbine.
d.
Plugged cooling holes (stage I
only).
Not permitted.
Replace gas turbine.
e.
Curled blade tip.
0.062 inch ( 1.57 mm) maximum on
leading and trailing edges.
Replace gas turbine.
f.
Hot gas corrosion (sulfidation).
Any amount of discoloration or surface
roughness. if there is no blistering,
splitting. or separation (delamination)
of the airfoil surface.
Replace gas turbine.
Airfoil for buildup of metal
splatter.
Any amount. if gas turbine performance is satisfactory.
Replace gas turbine.
Blade tip for burrs.
Any amount. if gas turbine performance is satisfactory.
Replace gas turbine.
(T
e·
h.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
Turbine Operating Hours 5000-10000
Elements of Turbine Blade Coat
Level
Chromium
80%
Natrium
60%
Carbondioxcide
70%
GEK 99441
010 00
Page 46
31 May 2002
h.
Carefully remove the borescope probe from the borescope port.
NOTE
There are two types ofborescope plugs S49. the screwdriver
slot bayonet type and the threaded type. Install the bayonet
type per step i. and the threaded type per step j.
1.
Install the bayonet type borescope plug S49 (figure 11. sheet I. detail A) as follow:
(I)
Align the borescope plug grooves with the pins in the borescope port and insert the plug into port. The
screwdriver slot in the plug must be approximately aligned with the UNLOCKED position on the rear main mount. See
detail B.
(2)
Insert a wide flat blade screwdriver in the slot of the plug.
I CAUTION t
Do not use excessive force when installing the borescope
plug or damage to the borescope plug and casing can occur.
(3) Push radially inward on the borescope plug approximately 0.20 inch (5.1 mm) and turn plug clockwise
approximately 45 degrees. Do not turn the plug once an increase in resistance is felt.
(4) Release pressure from the plug. The plug must move radially outward approximately 0.10 inch (2.5 mm)
and be correctly installed in the HPT casing as pressure is released. The slot in the plug must be aligned with the LOCKED
position on the rear main mount. See detail B .
.J.
Install the threaded type borescope plug S49 (figure 11. sheet 2. detail D) as follows:
(I)
Lubricate the external threads of the plug with magnesium hydroxide compound (untlavored milk of magnesia). See view E. Let the compound dry before installing the plug.
l CAUTION I
Do not use excessive force when installing the borescope
plug or damage to the borcscope plug and casing can occur.
(2)
Thread the plug into the HPT casing boss. See detail D.
(3)
Torque the plug to 50-60 lb in. (5.6-6.8 N·m).
(4)
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire borescope plug using the double-strand method
(WP 007 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 47
31 May 2002
10. BORESCOPE INSPECTION OF STAGES 3 THROUGH 5 LOW-PRESSURE TURBINE (LPT) ROTOR
BLADES.
NOTE
There are two types of bore scope plug S50. the bayonet type
and the threaded type. Remove the bayonet type per step a.
and the threaded type per step b.
a.
Remove the bayonet type borescope plug S50 (figure 12, sheet I. detail A) as follows:
(I)
Insert a :VS-inch drive into the borescope plug socket.
I CAUTION I
Do not use excessive force when removing the borescope
plug or damage to the borescope plug and casing can occur
b.
(2)
Press the borescope plug inward and rotate plug counterclockwise.
(3)
Remove the plug.
Remove the threaded type borescope plug S50 (figure 12. sheet 2, detail D) as follows:
I CAUTION I
Do not use excessive force when removing the borescope
plug or damage to the borescope plug and casing can occur.
(I)
Using a 3/8-inch drive or a 7/16-inch socket turn the plug counterclockwise until plug turns easily.
(2)
Remove the 3/8-inch drive or 7/16-inch socket from the plug.
(3)
Remove the plug.
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 48
31 May 2002
DETAIL A
BORESCOPE
PLUGS
LOW PRESSURE TURBINE STATOR BORESCAPE PORTS
DETAIL B
VIEW C
LOCKED@
(\CJ,
LOCKED
LOCKED
®
(\CJ,
GROOVES
(2 PLACES
180• APART)
PIN
(MAY OR MAY NOT
BE VISIBLE)
BORESCOPE
PLUG
UNLOCKED
BAYONET TYPE BORESCOPE PLUG
Figure 12.
1204052-00-A2A
LPT borescope Plugs Removal and Installation (Sheet I of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 49
VIEW E
DETAIL D
THREADED
BORESCOPE
THREADED
BORESCOPE
PLUG
PLUGS
THREADED TYPE BORESCOPE PLUG
Figure 12.
•
•
1204053-00-02
LPT borescope Plugs Removal and Installation (Sheet 2 of 2)
I CAUTION I
Only approved personnel is allowed to borescopeinspect the gas turbine. Incorrect inspection can cause
gas turbine removal that is not necessary.
Be sure the inlet turbine temperature is less than
l22°F (50°C) before you start the borescope procedure. Damage to the bore scope can occur if the temperature is more than 122°F (50°C).
NOTE
It will be easier to see the components to be inspected if you
use a rigid borescope 0.236 inch (6.0 mm) or less diameter.
and will view at a right angle.
c.
Turn the light source ON/OFF switch to the ON position and turn the brightness switch from the L position to
the H position.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
Page 50
31 May 2002
CAUTION
Be very careful and do not let the borescope probe touch the
internal parts of the gas turbine when you put probe into the
LPT casing port. Damage to the internal parts can occur.
NOTE
The compressor rotor and the high-pressure turbine (HPT)
rotor are not turned when you inspect the stages 3 through 5
low-pressure turbine (LPT) rotor blades.
d.
Carefully insert the borescope probe through the borescope port.
NOTE
The leading edge and the trailing edge of the rotor blades
can be seen from the same angle.
e.
Adjust the depth of the borescopc probe and turn the borescope probe until you can see the LPT rotor blades
(see figure 13 ). Inspect all LPT rotor blades. Refer to table 7 for inspection limits and corrective action.
f.
Turn the brightness switch on light source from the H position to the L position and turn the ON/OFF switch to
the OFF position.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
010 00
31 May 2002
Page 51
LPT BLADE TRAIUNG EDGE
LPT BLADE LEADING EDGE
1201073-00-A2A
LPT BLADE PLATFORM
Figure 13.
View of the LPT Rotor Blade Leading and Trailing Edges, the LPT Rotor Blade Platform,
and the LPT Stator Segment
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
010 00
GEK 99441
Page 52
31 May 2002
TABLE 7.
BORESCOPE INSPECTION OF STAGES 3 THROUGH 5 LPT ROTOR BLADES
Usable Limits
Corrective Action
(I) Cracks.
None permitted.
Replace gas turbine.
(2) Erosion at leading edge.
0.010 inch (0.25 mm) maximum erosion, if gas turbine performance is satisfactory.
Replace gas turbine.
(3) Nicks. pits, scratches, and
dents.
Any number. 0.005 inch (0.13 mm)
deep without high metal.
Replace gas turbine.
(4) Hot gas corrosion.
Any amount of distortion with no surface roughness. blistering, or separation of airfoil surface.
Replace gas turbine.
Trailing edge for bending and
twisting.
0.031 inch (0.79 mm) deviation from
straight line.
Replace gas turbine.
Inspect
a.
b.
Stages 3 through 5 rotor blades
for:
g.
Carefully remove the borescope probe from the borescope port.
NOTE
There are two types of bore scope plug S50, the bayonet type
and the threaded type. Install the bayonet type borescope
plug S50 (figure 12, sheet I. detail A) as follows:
h.
Install the bayonet type borescope plug S50 (figure 12. sheet I, detail A) as follows:
(I)
Align the borescope plug grooves with the pins in the borescope port and insert the plug into the port
I CAUTION I
Do not use excessive force when installing the borescope
plug or damage to the borescope plug and casing can occur
(2) Push inward on the borescope plug and turn plug counterclockwise until plug is engaged. Ensure the plug
and the turbine stator matchmarks are aligned in the LOCKED position. See detail B.
1.
Install the threaded type borescope plug S50 (figure 12. sheet 2, detail D) as follows:
(I)
Lubricate the external threads of the plug with magnesium hydroxide compound (untlavored milk of magnesia). See view E. Let the compound dry before installing the plug.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
Level Elements
0-5000
operating hrs
5001-10 000
operating hrs
10001 - 25 000
Chromium
90-100%
70-90%
50-70%
Oxygen
90-100%
70-90%
50-70%
Natrium
90-100%
70-90%
50-70%
Carbondioxcide
90-100%
70-90%
50-70%
GEK 99441
011 00
31 May 2002
Page 1 of 10
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
GAS TURBINE EXHAUST AREA AND EXHAUST CENTERBODY
INSPECTION, INSTALLATION, AND REMOVAL
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................
Inspection of Centervent Tube .........................................................
Inspection of Exhaust Centerbody ......................................................
Inspection of Gas Turbine Exhaust Area .................................................
Installation of Exhaust Centerbody ......................................................
Introduction ........................................................................
Removal of Exhaust Centerbody ........................................................
Replacement of Anchor Nuts ..........................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
2
6
6
2
6
I
6
9
1. INTRODUCTION. This work package provides instructions for inspecting (visually) the gas turbine exhaust area.
Also. this work package provides instructions for removing and installing the exhaust centerbody to allow the inspection of the
centervent tube for oil leakage.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
Bright Light
Grinder. Hand-Held Rotary
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
011 00
31 May 2002
3.
Page2
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Cloth. Abrasive
Local Purchase
Gloves, Thermally Insulated
Local Purchase
Oil, Lubricating
(MIL-L-7808 or MIL-L-23699)
Local Purchase
INSPECTION OF GAS 1URBINE EXHAUST AREA.
a.
Before inspecting the gas turbine exhaust area. do the following:
(I)
Shut down the gas turbine.
(2)
Deactivate the fire extinguishing system.
I WARNING I
Handling Hot Parts
•
•
•
When handling hot parts, wear approved gloves.
Handling of hot parts with bare hands may cause reddening and blistering of skin, or third-degree burns.
If skin is burned. immerse contacted area in cold
water for I 0 minutes. If pain or blistering persists.
immediately get medical attention.
(3)
Allow the gas generator to cool to room temperature. (Avoid contact with hot parts: wear thermally insulated gloves, if necessary.)
(4) Tag electrical switches "Out-Of-Service" to preclude inadvertent activation. Tag the gas turbine operating
controls "Do Not Operate"' to prevent starting during a desired shutdown condition.
b.
Remove customer equipment as follows:
(I)
Remove the insulation on aft exhaust duct.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
011 00
31 May 2002
Page3
CAUTION
While removing the V-band clamp. be careful not to allow
the aft exhaust duct to drop down and hit the inner exhaust
cone.
c.
(2)
Remove the V-band clamp from forward and aft exhaust duct section.
(3)
Push the aft exhaust duct into the exhaust collector as far as possible.
Inspect gas turbine exhaust area (table I).
TABLE 1.
Inspect
a.
INSPECTION OF GAS TURBINE EXHAUST AREA
Usable Limits
Max Repairable Limits
Corrective Action
Inner casing (6,
figure I ) for:
(I ) Cracks.
Any number, 1/4 inch
(6.4 mm) long. a minimum of
I inch (25 mm) apart.
Not repairable.
Replace exhaust frame.
(2) Dents.
Any number. 1/4 inch
(6.4 mm) deep, a minimum of
I inch (25 mm) from flange
where exhaust centerbody (4)
is attached.
Any number, any depth, a
minimum of I inch (25 mm)
from flange where exhaust
centerbody (4) is attached.
Cold-work dent
(WP 007 00) to usable
limit. White-light inspect
(WP 007 00) for cracks.
b.
Flanges (7) for nicks,
dents, and scratches.
Any number, 1/32 inch
(0.8 mm) deep. without high
metal. if 25 percent of original width of sealing surface is
intact.
Same as usable limits, with
high metal.
Remove high metal
(WP007 00).
c.
Outer casing (8) for:
(I) Cracks in parent
metal and welds.
None allowed.
Not repairable.
Replace exhaust frame.
(2) Dents.
Any number. I /8 inch
(3.2 mm) deep.
Any number, any depth.
Cold-work dent
(WP 007 00) to usable
limit. White-light inspect
(WP 007 00) for cracks.
d.
Struts (5) for cracks.
None allowed.
Not repairable.
Replace exhaust frame.
e.
Exhaust
centerbody (4) for:
Any number. 3/16 inch
(4.8 mm) long.
Not repairable.
Replace centerbody
(para 5).
(I) Cracks.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
011 00
31 May 2002
PageS
VIEW AFT LOOKING FORWARD
4
!
'
I
8
7
6
1. Stage 6 Turbine Blades
2. PT Speed Sensor Assembly
3. Vibration Sensor
4. Exhaust Centerbody
5. Strut (Qty 6)
6. Inner Casing
7. Flanges
8. Outer Casing
c
OOOLM5-058300
Figure I.
Inspection of Gas Turbine Exhaust Area
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
011 00
GEK 99441
Page6
31 May 2002
d.
Reinstall customer equipment as follows:
(I)
Pull the aft exhaust duct from the exhaust collector.
(2)
Align the aft exhaust duct with the forward exhaust duct.
(3) Using V-band clamp, secure the forward and aft exhaust ducts. Torque V-band clamp to 35 lb in.
(4.0 N ·m). Be sure that the V- band clamp is seated onto flange of exhaust ducts equally.
(4) Using a plastic mallet. tap the V-band clamp lightly around its circumference while increasing the torque to
75 lb in. (8.5 N·m). After 75 lb in. (8.5 N·m) torque value is reached, tap around the clamp again and check that the torque
remained at 75 lb in. (8.5 N·m).
(5)
5.
Reinstall insulation on aft exhaust duct.
REMOVAL AND INSTALLATION OF EXHAUST CENTERBODY.
a.
Remove exhaust centerbody (2, figure 2) as follows:
(I)
Remove six bolts (I) that secure centerbody (2) to exhaust frame (5 ).
(2)
Remove centerbody (2) by pulling it straight aft.
b.
Go to table 2 for inspection of centerbody and centervent tube (3 ).
c.
Install exhaust centerbody (2. figure 2) as follows:
(I) Align TOP mark on centerbody (2) with the 12 o'clock position on exhaust frame (5). Install centerbody
onto exhaust frame.
Lubricating Oil
66
(2)
Using lubricating oil MIL-L-23699 or MIL-L-7808, lightly lubricate the threads of six bolts (I).
(3)
Using six bolts (I). secure centerbody (2) to exhaust frame (5).
(4)
Cross-torque bolts (I) to 38-42lb in. (4.3-4.7 N·m).
(5) Insert a 0.050 inch ( 1.27 mm) thickness gage at location X. between centerbody (2) and centervent
tube (3 ). Gage must enter at any point 360 degrees. If gage does not enter. loosen bolts (I) and reposition centerbody as
necessary.
6.
INSPECTION OF EXHAUST CENTERBODY AND CENTERVENT TUBE.
Go to table 2.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
011 00
31 May 2002
Page7
/
2
LOCATION X
5
1. Bolt (Qty 6)
2. Exhaust Centerbody
3. Centervent Tube
(part of C-Sump Rear Cover)
4. Anchor Nut (Qty 6)
5. Exhaust Frame
c
OOOLM5-058400
Figure 2.
Removal, Inspection. and Installation of Exhaust Centerbody. and Inspection of Centervent Tube
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
011 00
GEK 99441
Page 8
31 May 2002
TABLE 2.
Inspect
a.
INSPECTION OF EXHAUST CENTERBODY AND CENTERVENT TUBE
Usable Limits
Max Repairable Limits
Corrective Action
Exhaust centerbody
(2, figure 2) for:
(I ) Cracks in:
b.
c.
(a) Shell/cone.
Any number. 3116 inch
(4.8 mm) long.
Not repairable.
Replace centerbody
(para 5).
(b) Stiffener.
Any number, 1/8 inch
(3.2 mm) long.
Not repairable.
Replace centerbody
(para 5).
(2) Dents.
Any number. 1/8 inch
(3.2 mm) deep.
Any number.
Cold-work dent
(WP 007 00) to original
contour.
(3) Nicks and
scratches.
Any number. I /64 inch
(0.4 mm) deep, without high
metal.
Same as usable limits. with
high metal.
Blend high metal
(WP 007 00).
(I) Locking action.
Usable if bolt (I) cannot be
threaded through entire nut by
hand.
Not repairable.
Replace nut (para 7).
(2) Damaged threads.
Up to one thread cumulative,
if bolt (I) can be threaded
into nut.
Not repairable.
Replace nut (para 7).
(I) Cracks.
None allowed.
Not repairable.
Replace exhaust frame.
(2) Evidence of oil
Not allowed.
Not repairable.
Replace exhaust frame.
Any number, 0.0 I 0 inch
(0.25 mm) deep. without high
metal.
Same as usable limits. with
high metal.
Blend high metal
(WP 007 00).
Anchor nuts (4) for:
Centervent tube (3)
for:
leakage or coked
oil.
(3) Nicks and
scratches.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
011 00
31 May 2002
7.
Page 9/10
REPLACEMENT OF ANCHOR NUTS.
I WARNING I
Power Grinding
•
•
•
•
Avoid prolonged or repeated contact with dust. Inhalation of dust may cause temporary coughing and
wheezing. respiratory tract irritation. and permanent
lung problems. If coughing or wheezing persists. get
medical help.
If dust contacts eyes. tlush them thoroughly with
water.
When using an air-exhausted grinding wheel. wear
approved respirator. goggles, or face shield.
If grinder is not equipped with local exhaust ventilation, wear an appropriate respirator and goggles or
face shield.
a.
Using a hand-held rotary grinder, carefully grind off the damaged anchor nut. Do not grind into parent metal of
exhaust frame.
b.
Blend the area (WP 007 00) with abrasive cloth to remove all traces of nut retainer.
c.
Using weld data (table 3). tack weld a new anchor nut at two locations 180 degrees apart.
TABLE 3.
Material to
be Welded
AMS 5735
Welding Rod
Specification
or
Designation
Hastelloy W
(AMS 5786)
Size
(Dia)
0.030-0.062
inch (0.761.57 mm)
WELD DATA
Torch Gas
Flow
Argon 8-14
CFH (0.230.40 m 3/hr)
Backup Gas
Flow
Argon or
Helium as
required
Weld
Contour
Current
(Amperes)
25-30
Tack Weld
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 1 of 14
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
VARIABLE STATOR VANES (VSV) SYSTEM
INSPECTION AND RIGGING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................
Inspection of VSV System ............................................................
Introduction ........................................................................
Rig Check of VSV System (Operating Condition) ..........................................
Rigging of VSV System (Static Condition) ...............................................
Support Equipment ..................................................................
.
.
.
.
.
.
2
2
6
4
1. INTRODUCTION. This work package provides instructions for inspecting and rigging the Variable Stator Vanes
(VSV) system.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
IC7304GOI
Set, VG Actuation Control
IC7307GOI
Indicator, VSV Position
8600A-OI
Voltmeter. Digital
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
3.
Page2
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Adhesive. RTV I 06 Silicone Rubber
(MIL-A-46106 or MIL-A-46106A)
GE Silicone Products Division
260 Hudson River Road
Waterford. NY 12188-191 0
USA
or
GE Silicones
5 Mail Joliot Curie
95-ST Ouen L'Aumone
95004 Cergy
France
Caps. Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
Plugs. Protective
Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
INSPECTION OF VSV SYSTEM.
a.
or binding:
Inspect the following components of the VSV system (see figure I) for evidence of leakage, looseness. damage,
•
•
•
•
•
•
Actuator hose assembly (I)
Actuator rings (2)
Actuator shaft (3)
VG actuator (4)
Feedback arm (5)
Feedback cable (6).
b. If any components listed in step a. show evidence of damage, refer to WP 028 00 or WP 029 00 for further
inspection and, if necessary. replacement of components.
c.
Inspect CIT sensor for damage. Replace CIT sensor (WP 009 00) if necessary.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
012 00
GEK 99441
Page3
31 May 2002
2
LEFT SIDE
TOP VIEW
1. Actuator Hose Assembly
2. Actuator Rings
3. Actuator Shaft
4. VG Actuator
5. Feedback Arm
6. Feedback Cable
RIGHT SIDE
c
OOOLM5-058600
Figure I.
Inspection of Variable Stator Vanes (VSV) System Components
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
012 00
GEK 99441
Page4
31 May 2002
5.
RIGGING OF VSV SYSTEM (STATIC CONDITION).
Hydraulic Fluid
71
NOTE
Have a 5-gallon (191iters) container at hand to catch
hydraulic fluid from VG actuator head hose (9. figure 2.
view A) and rod hose (11 ).
a.
Disconnect VG actuator head hose (9. figure 2. view A) from head end manifold tee (5). Install protective plug
at end of head hose.
b.
Disconnect VG actuator rod hose ( 11) from rod end manifold tee (8 ). Install protective plug at end of rod hose.
c.
Connect head hose (3), of VG actuation control set IC7304GOJ (I), to head end manifold tee (5).
d.
Connect rod hose (7), of VG actuation control set I C7304GO I (I), to rod end manifold tee (8 ).
e.
Position selector valve (15) to the NEUTRAL position.
f.
Connect a source of compressed air to the quick-disconnect fitting (2). Adjust pressure regulator to maintain
30-35 psig (207-241 kPa). If a source of compressed air is not available, use a high-pressure nitrogen bottle with regulator
(regulator must be preset to 200 psi ( 1379 kPa) maximum before connecting to control set (I)).
g. Move selector valve (15) to the OPEN position so that actuator rings on gas turbine move counterclockwise and
actuator rods on VG actuators (4, 6) are fully extended (vanes are in the fully-open position).
h. Move selector valve ( 15) to the CLOSED position so that actuator rings on gas turbine move clockwise and actuator rods on VG actuators (4, 6) are fully retracted (vanes are in the fully-closed position).
1.
If vanes are at or near the fully-closed position. repeat steps g and h to cycle the actuator rings to be sure that the
vanes at the fully-closed position.
j.
Check the rig position of the feedback lever arm (I 0. view A) by checking the alignment of the pointer on lever
arm with the rig mark on the VG control indicator plate ( 12 ). If marks are not aligned. do the following:
(I) Remove lock wire and loosen jam nuts on either side of the feedback cable ( 13 ). Rotate turnbuckle until the
pointer on lever arm (I 0) is aligned with the rig mark on indicator plate ( 12).
(2)
Torquejamnuts to 135-150 lb in. (15.3-16.9 N·m). Do not lock-wirejamnuts at this time.
(3) Cycle the actuator rings and check that the feedback cable ( 13) is not bottomed out internally at either end
of the actuator stroke.
k. Position selector valve ( 15) to the NEUTRAL position. Remove source of compressed air from quick-disconnect fitting (2).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
PageS
3
1/
0 f
I
15
PRESSURE
GAGE
),
I
6
\
i.
14
_......ACCESSORY
GEARBOX
ASSEMBLY
8
I
I
!I
!
\
1. VG Actuation Control
Set 1C7304G01
2. Quick-Disconnect Fitting
3. Head Hose
4. VG Actuator
5. Head End Manifold Tee
6. VG Actuator
7. Rod Hose
8. Rod End Han1fold Tee
9. VG Actuator Head Hose
10. Feedback Lever Arm
11. VG Actuator Rod Hose
12. VG Control Indicator Plate
13. Feedback Cable
14. Pressure Regulator
15. Selector Valve
VG CONTROL ASSEMBLY
VIEW A
Figure 2.
c
OOOLMS-058700
Rigging ofVSV System (Static Condition). Using VG Actuation Control Set IC7304GOI
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 6
I.
Disconnect rod hose (7) from rod end manifold tee (8).
m.
Disconnect head hose (3) from head end manifold tee (5).
n. Connect VG actuator rod hose ( 11) to rod end manifold tee (8 ). Torque hose connection to 135-150 lb in.
(15.3-16.9 N·m).
o.
Connect VG actuator head hose (9) to head end manifold tee (5). Torque hose connection to 180-200 lb in.
(20.3-22.6 N·m).
CAUTION
Gas turbine must be operated at IDLE speed for 5 minutes
following the first start after rigging the VSV system. This
is necessary to purge entrapped air from VG actuators and
supply hoses before accelerating to operating speed: otherwise, gas turbine could stall.
p.
Do an idle speed check and operate gas turbine for 5 minutes: shut down gas turbine. Do a VSV rig check
(para 6).
6.
RIG CHECK OF VSV SYSTEM (OPERATING CONDITION).
a.
Preliminary Instructions.
(I)
The VSV system rig check must be done during the first operation of a new or overhauled gas turbine. The
VSV system should be checked at several points during operation between IDLE and 17,000 rpm (corrected).
(2) The VSV system rig check must be done periodically to check the VSV linkage for wear or if the VG
schedule has shifted.
(3)
The VSV system rig check must also be done after the adjustment, repair, or replacement of the VG control
assembly, feedback cable, or any VG components.
b.
Setup of VSV System Rig Check.
(I)
Install VSV position indicator I C7307GO I (see figure 3, sheet I ) as follows:
(a)
Remove three Jocknuts and three 7/8 inch (22.2 mm) long shoulder bolts ( 11) from compressor casing-to-front frame flange at boltholes No. 60. 61, and 62.
(b)
Position bracket (I) (part of indicator I C7307GO I) onto boltholes No. 60. 61, and 62.
(c)
Using three 1-1/8 inches (28.6 min) long bolts PN MS9751-16 ( 10) and locknuts. secure bracket (I)
to compressor casing flange. Torque locknuts to 105-115 lb in. (11.9-13.0 N·m).
(d) Position extension shaft (9) onto the third vane spindle of stage I so that the hex flat on shaft aligns
with hex tlat of vane lever locknut. Be sure there is a 0.003-0.0 I 0 inch (0.08-0.25 mm) gap as shown.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page7
2
VSV POSITION
INDICATOR 1C7307G01
15
ALL DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
"!rlFRAME
( REF)
t
I
I
.
.
I
i
I
I
I
'
:
I
I
I
:
sTAGE 1
THIRD VANE SPINDLE
{REF)
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Bracket
Potentiometer
Lead Assembly
Connector
Potentiometer Shaft
Cl amp
Bellows
Cl amp
Extension Shaft
Bolt PN MS9751-16
Shoulder Bolt
Lock Sleeve
Mount Rod
Position Sensor Assembly
Bolt
!.
BOLTHOLE
19'34'{REF)
---+--·--Jr-3
.
9
O'CLOCK
COMPRESSOR CASING
SPLITLINE
COMPRESSOR CASING-TO-FRONT FRAME
BOLTING DIAGRAM
VIEW AFT LOOKING FORWARD
c
001LM5-058800
Figure 3.
Rig Check ofVSV System (Operating Condition). Using VSV Position Indicator IC7307GOI (Sheet I of2)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
012 00
PageS
31 May 2002
2. Potentiometer
4. Connector
i
I
,-----------,
L
....__ _
A <' CLIP
BLACK
B
c
COMMON
I
RED
CLIP
INDICATOR
PLAIN
TEST
CLIP
DIGITAL
1 - VOLTMETER
8600A-Ol
I
I
I
1201074-00-02
L----------.J
Figure 3.
Rig Check ofVSV System (Operating Condition), Using VSV Position Indicator IC7307GOI (Sheet 2 of2)
RTV Silicone Rubber Adhesive/Sealant,
95
MIL-A-461 06 or MIL-A-461 06A
RTV-60 Silicone Rubber Potting Compound,
MIL-1-468388
(e) Slide Jock sleeve (12) over extension shaft (9) to prevent loosening during gas turbine operation.
Secure lock sleeve with a small amount of RTV I 06 silicone rubber adhesive (MIL-A-461 06 or MIL-A-461 06A).
(2)
(f)
Assemble clamps (6. 8) and bellows (7) onto extension shaft (9).
(g)
Insert mount rod ( 13) of position sensor assembly ( 14) in bracket (I).
(h)
Align potentiometer shaft (5) with extension shaft (9).
(i)
Slide bellows (7) up into potentiometer shaft (5).
(j)
Tighten bolt (15) and clamp (6). Do not tighten clamp (8).
Adjust bellows (7) and potentiometer (2) as follows:
(a) Using digital voltmeter 8600A-OI, verify that there are 4,500-5.500 ohms between pins A and C
(sheet 2) on potentiometer (2).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
012 00
GEK 99441
Page9
31 May 2002
(b)
Connect leads of voltmeter to connector (4) as shown in schematic (sheet 2). Zero the voltmeter.
(c) With the variable stator vanes in the fully-closed position (gas turbine is shutdown), rotate
bellows (7) so that potentiometer reading on voltmeter is 2.760-2,800 ohms. Tighten clamp (8. sheet I).
(3) Connect lead assembly (3) to connector (4 ). Route the other end of lead to outside area of gas turbine.
Connect lead to digital voltmeter.
c.
Performing Running Rig Check.
(I) Start gas turbine and stabilize at idle speed. Gas generator (GG) rotor speed should reach approximately
11.200 rpm and power turbine (PT) shaft speed should reach approximately 5,000 rpm with no load.
(2)
Observe the resistance reading on digital voltmeter.
(3)
Record the following data in applicable blocks in figure 4:
•
•
•
Resistance reading
GG rotor speed
PT shaft speed.
(4) Enter the recorded resistance reading on the graph in figure 4 and obtain the VSV position beta angle.
Record the obtained beta angle in applicable block.
(5)
Determine the VSV system schedule as follows:
(a)
Enter the recorded VSV position beta angle in figure 5 and figure 6.
(b)
Observe and record gas turbine air inlet temperature in figure 5.
NOTE
•
•
Figure 5 provides VSV system schedule limits without the correction to standard temperature.
Figure 6 provides VSV system schedule limits corrected to standard temperature.
•
For initial running rig check. it is preferred to use limits in figure 6.
(c) Using either figure 5 or 6. determine VSV position schedule (vanes open or closed) for a given beta
angle, GG rotor speed, and air inlet temperature.
(6)
If VSV position schedule is out of limits. do the following:
(a)
Shut down gas turbine.
NOTE
Lengthening the feedback cable ( 13. figure 2) will close the vanes.
(b) Loosen jam nuts on either side of feedback cable ( 13 ). Rotate turn buckle as required to achieve nominal position as shown in figure 6.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 10
62.1
60
--- -- --
RIG POSITION
0
0
--
-- -- -- -- -- --
V)
UJ
UJ
IX
'-"
UJ
50
VANES
CLOSED
0
0
/
UJ
...J
'-"
z:
/
L
/
V
V"
<(
<(
UJ
40
0
CD
-z:
,/
0
V)
0
c..
>
>
V)
30
0
VANES
20 '!-OPEN
10
0.21
/
/
/
/
V
/
0
0.23
0.22
0.24
0.25
0.26
0.27
0.28
RESISTANCE (OHMS)
OHMS
RESISTANCE READING
RPM
GG ROTOR SPEED
RPM
PT SHAFT SPEED
r--------i
DEGREES
VSV POSITION BETA ANGLE
c
OOOLMS-058900
Figure 4.
Determining VSV Position Beta Angle
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 11
Vl
UJ
UJ
0::
""
UJ
0
UJ
--'
""
z:
<
<
f-
LU
""z:
0
>
Vl
>
200
___ --- - - - - - - - - - - - -
t-
h
K"\
'\ )..
--
--
CONTROL STOP
!
4,000
I
I
I
6,000
1
I I
I
8,000
I I
I
10,000
I i_U_l J I U
12,000
_ll_U_
..1
Ill I I
I
I_LU
Llll
I
14,000
16,000
18,000
20,000
GG ROTOR SPEED (RPM)
!J. GG ROTOR SPEED
!J. AIR INLET TEMPERATURE
°F (
°C)
13.939 RPM/DEGREE
=
I
AIR INLET TEMPERATURE
NOTE
CONSTANT 13.939 RPM/DEGREE TO BE
USED IN FIGURE 6 FOR CORRECTING
INLET AIR TEMPERATURE.
c
OOOLM5-059000
Figure 5.
VSV System Schedule (Not Corrected to Standard Temperature)
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 12
[CAUTION
I
IF GAS TURBINE HAS BEEN OPERATED ABOVE IDLE SPEED WITH VSV
POSITION (STAGE 1 STATOR VANE ANGLE) MORE THAN 3 DEGREES
BELOW THE OPEN LIMIT AT THE IDLE CHECK POINT OR MORE THAN
2.5 DEGREES BELOW THE OPEN LIMIT AT THE HIGH SPEED CHECK
POINT (15,000- 16,720 RPM), STAGE 1 COMPRESSOR BLADES
MUST BE REPLACED.
70°
RIG POSITION
62.1 0
' l'.."-
...... 60 ol.....
.....
""'
V)
0::
el
.....
0
.......
....--'
el
z:
'"'\'
50
<
<
1-
....
<0
MAXIUM OPEN_
LIMIT
z:
..... 40
1.....
0
MAXIUM CLOSED
LIMIT
!.--
I
f\\\
V)
0
c..
>
>
V)
30
.;:
'\
=
=
:
20
'\
.:
:
::; 11 I
I 11 I
1111
1111
5,000
1111
I 11 I
1111
1111
1111
11 11
1111
'"
1111
1111
15,000
10,000
1111
1111
1111
1111
20,000
GG ROTOR SPEED (RPM)
CORRECTION FOR AIR INLET TEMPERATURE
GG ROTOR SPEED (NOMINAL)
=
L
ROTOR SPEEDl + 13.939
(ACTUAL)
J
1201075-00-A2A
Figure 6.
VSV System Schedule (Corrected to Standard Temperature)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
012 00
31 May 2002
Page 13/14
(c)
(d)
method (WP 007 00).
Torquejamnuts to 135-150 lb in. (15.3-16.9 N·m).
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire jamnuts using the double-strand
CAUTION
Do not allow vane position to exceed the limits given in figure 6 during the running rig check. If limits are exceeded,
stage I compressor blades will get damaged.
(7)
Start gas turbine and stabilize at idle speed.
(8)
While increasing GG rotor speed at increments of I .000-1.500 rpm until vanes are fully open, do the
following:
(a) Set control to AUTO position and increase gas turbine loads with bypass control to obtain GG rotor
speed above idle with control system. Using procedures in steps (2) through (5). determine and plot VSV position at each set
point. Do not adjust feedback cable length to reach nominal when GG rotor speed is above idle.
(9)
Review VSV position schedule for data entered in figure 5 or 6 from step (8).
(I 0) If VSV position schedule is out of limits. troubleshoot for the following conditions:
•
•
•
•
•
Loose or damaged feedback cable
Improperly calibrated or loose VSV position indicator I C7307GO I
Loss of hydraulic pressure
Sticking VG actuator
Defective VG control.
( 11) If VSV position schedule is within limits, record final VSV position and GG rotor speed as baseline data.
Retain data for future reference.
d.
Removal of VSV Position Indicator I C7307GO I.
(I)
Loosen bolt ( 15. figure 3) and clamps (6. 8). Remove position sensor assembly ( 14) from stage I third
vane spindle.
(2) Remove three locknuts and three bolts (I 0) from bracket (I). Remove bracket from compressor
casing-to-front frame flange.
(3)
Reinstall three shoulder bolts ( 11 ). boltheads forward, into boltholes No. 60, 61, and 62. Secure bolts with
(4)
Torque locknuts to I 05-115 lb in. (11.9- 13.0 N·m).
locknuts.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
013 00
31 May 2002
Page 1 of 8
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
CHIP DETECTORS AND DRAIN PLUG
REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Chip Detectors ......................................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Consumable Materials ................................................................
Drain Plug .........................................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
General Information .................................................................
Introduction ........................................................................
Support Equipment ..................................................................
Page No.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4
5
6
6
4
2
4
5
6
6
4
2
1. INTRODUCTION. This work package provides instructions for removing. cleaning. inspecting, and installing the chip
detectors drain plug as determined by the periodic inspections and maintenance table in WP 008 00.
2.
SUPPORT EQUIPMENT.
None
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
013 00
GEK 99441
Page2
31 May 2002
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Cloth. Lint-Free
Local Purchase
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
Solvent, Dry Cleaning (Stoddard Solvent)
P-D-680
Local Purchase
Tape. Masking
Local Purchase
GENERAL INFORMATION.
a.
There are four chip detectors (see figure I) on the LMSOO gas turbine located at:
One chip detector (3, view A) in fitting on A-sump scavenge tube (I)
One chip detector (6, view B) in fitting on C-sump forward scavenge tube (4)
One chip detector (9, view C) on aft end of accessory drive gearbox assembly (7)
One chip detector ( 12. view D) in screen insert tee (I 0) on lube and scavenge pump
b. There is also a drain plug ( 13, view C) located approximately at the 6 o'clock position on the aft end of the accessory drive gearbox assembly (7). Materials such as non-metallic sludge, small silver or non-magnetic flakes, or bronze powder. or machining chips of aluminum will accumulate on drain plug.
c.
During normal gas turbine operation, some accumulation of fuzz-like magnetic particles (see figure 2, view A)
will be found on chip detectors when they are removed and inspected. Other materials such as nonmetallic sludge, small silver
or non-magnetic flakes, or bronze powder or machining chips of aluminum (the latter especially on new gas turbines) will
accumulate on drain plug. The amount will vary but should not be cause for gas turbine removal.
d.
Hair-like slivers of magnetic particles up to I inch (25 mm) long may be found on chip detectors and should not
be cause for gas turbine removal.
e.
Flakes of magnetic material (view B) 1/64 inch (0.4 mm) diameter or more may indicate a pending failure. This
condition is cause for gas turbine removal.
f.
Chunks of metallic material I /32 x I /32 inch (0.8 x 0.8 mm) or more, other than fuzz or hair-like slivers, are also
cause for gas turbine removal.
g. If there is evidence of contamination on the chip detectors, service (WP 019 00) the lube filter, the lube and scavenge pump. and the A-sump scavenge pump.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
013 00
Page3
31 May 2002
VIEW B
VIEW A
(ALL MODELS
EXCEPT L32119G06)
LUBE AND SCAVENGE
PUMP ASSEMBLY
B-SUMP AFT SCAVENGE
HOSE ASSEMBLY
VIEW C
1.
2.
3.
4.
5.
6.
7.
VIEW D
A-SUMP SCAVENGE TUBE
PACKING
CHIP DETECTOR
C-SUMP FORWARD SCAVENGE TUBE
PACKING
CHIP DETECTOR
ACCESSORY DRIVE GEARBOX ASSEMBLY
8.
9.
10.
11.
12.
13.
14.
PACKING
CHIP DETECTOR
SCREEN INSERT TEE
PACKING
CHIP DETECTOR
DRAIN PLUG
PACKING
1201 094-00-A2A
Figure I.
Location of Chip Detectors and Drain Plug
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
013 00
31 May 2002
Page4
METALLIC FUZZ ON CHIP DETECTOR
METALLIC CHIPS ON CHIP DETECTOR
VIEW A
VIEW 8
c
OOOLM5-04010A
Figure 2.
5.
Accumulation of Metallic Material on Chip Detectors
REMOVAL OF CHIP DETECTORS AND DRAIN PLUG.
a.
Remove lockwire from four chip detectors (3. 6, 9. 12, figure 1. views A through D), and from drain plug
( 13, view C).
I WARNING I
Removing Magnetic Chip Detectors
To prevent being burned by hot oil. wear protective gloves
when removing chip detectors.
Lubricating Oil
66
b. (All models except L32119G06) Remove chip detector (3, view A) from fitting on A-sump scavenge tube (I),
located at the 4 o'clock position (forward looking aft), half way up the compressor casing. Discard packing (2).
c.
Remove chip detector (6, view B) from fitting on C-sump forward scavenge tube (4 ). located at the 4 o'clock
position (forward looking aft). Discard packing (5).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Elements of Turbine Blade Coat
Level
Oxygen
45%
Natrium
60%
Carbondioxcide
70%
GEK 99441
013 00
31 May 2002
Page 5
d.
Remove chip detector ( 12. view D) from the screen insert tee (I 0), located on the lube and scavenge pump
assembly. Discard packing ( 11 ).
e.
Remove chip detector (9. view C) from aft end of accessory drive gearbox assembly (7), located at the 7 o'clock
position (aft looking forward). Discard packing (8).
f.
6.
Remove drain plug ( 13) from gearbox assembly (7). Discard packing ( 14 ).
CLEANING OF CHIP DETECTORS AND DRAIN PLUG.
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
a.
Immerse chip detector or drain plug in a container filled with clean dry cleaning sol vent P-D-680, or equivalent.
Swish part around several times to dislodge any material.
b.
Using a lint-free cloth, wipe part clean.
I WARNING I
Compressed Air
When using compressed air for any cooling. cleaning,
or drying operation, do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench. wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench, wear approved respirator and goggles.
c.
Using filtered, clean. dry compressed air. remove any particles remaining on part.
d.
Using masking tape. remove any small particles remaining on part by using the adhesive side of tape. Repeat
this process until there are no metal particles on part.
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
013 00
GEK 99441
Page6
31 May 2002
7.
INSPECTION OF CHIP DETECTORS AND DRAIN PLUG.
Go to table I.
TABLE 1.
INSPECTION OF CHIP DETECTORS AND DRAIN PLUG
Usable Limits
Inspect
Max Repairable Limits
Corrective Action
Chip detectors and drain
plug for:
a.
Cracks.
None allowed.
Not repairable.
Replace detector or plug.
b.
Damaged. missing. or
crossed threads.
Up to one full thread damaged or missing, without
high metal.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00) and chase
damaged threads. Clean
part (para. 6).
c.
Leaks (during gas
turbine operation).
None allowed.
Not repairable.
Replace detector or plug.
d.
Magnet strength.
Magnet must support weight
of detector or plug when
inverted against a steel
surface.
Not repairable.
Replace detector or plug.
e.
Scratches on washer
face.
Amy number, 0.003 inch
(0.08 mm) deep. without
high metal.
Not repairable.
Replace detector or plug.
8.
INSTALLATION OF CHIP DETECTORS AND DRAIN PLUG.
a.
(All models except L32119G06) Install chip detector (3. figure I. view A) as follows:
(I)
Install packing (2) onto chip detector (3).
(2) Install chip detector (3) into fitting on A-sump scavenge tube (I). located at the 4 o'clock position
(forward looking aft).
(3)
Torque chip detector (3) to 155-175 lb in. (17 .5-19.8 N·m).
(4)
Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire chip detector (3) using the doublestrand method
(WP007 00).
b.
Install chip detector (6, view B) as follows:
(I)
Install packing (5) onto chip detector (6).
(2) Install chip detector (6) into fitting on C-sump forward scavenge tube (4 ), located at the 4 o'clock position
(forward looking aft).
(3)
Torque chip detector (6) to 155-1751b in. (17.5-19.8 N·m).
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
GEK 99441
013 00
Page 7/8
31 May 2002
(4)
Using 0.032 inch (0.81 min) diameter lockwire, lock-wire chip detector (6) using the doublestrand method
(WP 007 00).
c.
Install chip detector (12, view D) as follows:
(I)
Install packing ( 11) onto chip detector ( 12).
(2)
Install chip detector (12) into screen insert tee (I 0). located on the lube and scavenge pump assembly.
(3)
Torque chip detector (12) to 155-175lb in. (17.5-19.8 N·m).
(4) Using O.O:U inch (0.81 mm) diameter lock wire. lock-wire chip detector (12) using the doublestrand
method (WP 007 00).
d.
Install chip detector (9. view C) as follows:
(I)
Install packing (8) onto chip detector (9).
(2) Install chip detector (9) on aft end of accessory drive gearbox assembly (7) at the 7 o'clock position
(aft looking forward).
(3)
Torque chip detector (9) to 150-200 lb in. (16.9-22.6 N·m).
(4)
Using 0.032 inch (0.81 mm) diameter lock wire. lock-wire chip detector (9) using the doublestrand method
(WP 007 00).
e.
Install drain plug (13, view C) as follows:
(I)
Install packing (14) onto drain plug ( 13 ).
(2) Install drain plug ( 13) on the aft end of the accessory drive gearbox assembly (7) at approximately the
6 o'clock position.
(3)
Torque drain plug ( 13) to 155-175 lb in. ( 17.5-19.8 N·m).
(4)
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire drain plug ( 13) using the doublestrand method
(WP 007 00).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
014 00
GEK 99441
Page 1 of 12
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
PRESERVATION OF INSTALLED GAS TURBINES
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Consumable Materials ................................................................
Introduction ........................................................................
Oil Wetting (Slushing) of Gas Turbine Bearings ...........................................
Preservation of Fuel System (Marine Only) ...............................................
Preservation of Gas Turbines to be Inactive Up to 30 Days ...................................
Preservation of Gas Turbines to be Inactive for More than 30 Days, but are on Stand by Status .......
Preservation of Gas Turbines to be Inactive for More than 30 Days Without Standby Status .........
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
2
I
4
11
2
3
3
I
1. INTRODUCTION. This work package defines the criteria and procedures for preserving the LM500 gas turbines for a
short term (up to 30 days) or extended period (longer than 30 days). The purpose of these procedures is to limit or prevent contamination and corrosion in the gas turbine during layup or storage. when the gas turbine is not returned to the controlled environment of its shipping container.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
IC3569G03
Pump, Pressurizer
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
014 00
31 May 2002
3.
Page 2
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Caps. Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Desiccant, Type I (MIL-D-3464)
Davidson Chemical Co.
Baltimore. MD
USA
Filter, !O-Micron
Local Purchase
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
MateriaL WaterproofNaporproof
(MIL-B-131)
Local Purchase
OiL Lubricating (MIL-L-6081)
Grade 1010
Royal Lubricating Co., Inc.
P.O. Box 518
River Rd.
East Hanover, NJ 07936
USA
OiL Lubricating (MIL-L-23699)
Local Purchase
Oil, Preservative (Brayco 599)
Bray Oil Company
1925 North Mariana Ave.
Los Angeles, CA 90032
USA
PRESERVATION OF GAS TURBINES TO BE INACTIVE UP TO 30 DAYS.
a.
Water-wash (WP 017 00) gas turbine.
b.
Disconnect ignition system by removing the low-voltage input lead from ignition exciter (WP 023 00). Using
protective cap, cover the input lead.
c.
Cover all openings, including the gas turbine inlet and exhaust. using waterproof/vaporproof material
MIL-B-131.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
014 00
GEK 99441
31 May 2002
Page3
5. PRESERVATION OF GAS TIJRBINES TO BE INACTIVE FOR MORE THAN 30 DAYS, BUT ARE ON
STANDBY STATUS. Gas turbines that will be inactive for more than 30 days, but are on standby status with all services
available, must be started every 15 days as follows:
a.
Do prestart system checks (WP 005 00 for Industrial Gas Turbines or WP 005 I 0 for Marine Gas Turbines).
b.
Remove covers from all openings. including the gas turbine inlet and exhaust.
c.
Operate gas turbine at idle speed for 5 minutes, or motor the gas turbine for 30 seconds, after indication of oil
pressure. Allow gas turbine to coast down.
d.
Cover all openings, including the gas turbine inlet and exhaust. using waterproof/vaporproof material
MIL-B-131.
6. PRESERVATION OF GAS TIJRBINES TO BE INACTIVE FOR MORE THAN 30 DAYS WITHOUT
STANDBY STATUS. Gas turbines that will be inactive for more than 30 days and will not be started, must be preserved as
follows:
a.
Install a multi-level humidity indicator in the gas turbine compartment. The indicator should be visible and
should not interfere with any waterproof/vaporproof material.
b.
Monitor the humidity level in the gas turbine compartment every 14 days. The humidity level must be within the
limits given in table I.
TABLE 1.
HUMIDITY LEVEL LIMITS
Ambient Temperature
Relative Humidity
-5°F to +35°F (-21 oc to -2°C)
509'o or less
Below -5°F (-21 °C)
607< or less
c.
If the humidity level in the gas turbine compartment is at the upper limit of acceptable range, monitor the compartment every 7 days until humidity level decreases.
d.
If the humidity level in the gas turbine compartment is out of limits, take the following corrective actions within
the time interval given in table 2:
(I)
Replace desiccant bags, type I MIL-D-3464.
(2)
Install mechanical dehumidifiers.
(3)
Install pumps to draw dry air into the compartment.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
014 00
Page4
31 May 2002
TABLE 2.
CORRECTIVE ACTION TIME LIMIT FOR UNACCEPTABLE HUMIDITY LEVELS
Humidity Indication at Ambient Temperatures of:
Below -5°F
(-21 QC)
-5°F to +35°F
(-21°C to +2°C)
Above 35°F
(20C)
Time for
Corrective Action
Above 600<
Above 500<
Above 40%
3 weeks
Above 700<
Above 60'7r
Above 50'7r
2 weeks
Above 800(
Above 709<
Above 60o/c
I weeks
e.
If the corrective action given in step d is not accomplished within the time intervals of table 2, do the following:
(I)
Oil-wet (slush) gas turbines hearings (para 7) every 60 days.
(2) Monitor the humidity level in the gas turbine compartment in accordance with table I within 60 days;
otherwise, gas turbine bearings must be oil-wetted again.
7.
OIL WETTING (SLUSHING) OF GAS TURBINE BEARINGS.
NOTE
The oil wetting (slushing) of gas turbine hearings must he
done when the humidity level in the gas turbine compartment cannot he maintained below 40'7c.
a.
Set up pressurizer pump I C3569G03 (see figure I) as follows:
Lubricating Oil
(I)
oil Brayco 599.
(2)
h.
66
Thoroughly mix 6 gallons (23 liters) of lubricating oil MIL-L-23699 with 2 quarts (2 liters) of preservative
Pour oil mixture into reservoir of pressurizer pump.
Remove customer equipment that prevents access to applicable areas of gas turbine sump bearings and to AGB
cranking pad.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
014 00
31 May 2002
Page 5
1201 095-00-02
Figure I.
c.
Pressurizer Pump I C3569G03
Oil-wet (slush) C-sump bearings (see figure 2) as follows:
(I)
Place a suitable container under the resistance temperature detector (RTD) (I) to catch oil drainage.
Lubricating Oil
66
(2)
Disconnect coupling nut (2) on C-sump oil supply tube (3) from RTD (I). Allow oil to drain into
(3)
Connect pressurizer pump supply hose to coupling nut (2) on C-sump oil supply tube (3). Tighten nut.
container.
(4) Reposition container under chip detector (6) located at the 5:30 o'clock position (forward looking aft) on
C-sump aft scavenge tube (4 ).
(5) Remove lockwire from chip detector (6). Remove chip detector with packing (5). Remove and discard
packing. Allow any oil to drain into container.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
014 00
GEK 99441
Page6
31 May 2002
1. Resistance Temperature
Detector (RTD)
2. Coupling Nut
3. C-Sump Oil Supply Tube
4. C-Sump Aft Scavenge Tube
5. Packing
6. Chip Detector
1201096-00-02
Figure 2.
Oil Wetting (Slushing) of C-Sump Bearings
NOTE
The handle of pressurizer pump must be operated rapidly
through the full piston stroke so that the proper amount of
oil/preservative mixture is supplied to the C-sump bearings.
(6) Using a strap wrench or other acceptable methods. rotate the power turbine rotor at 5-l 0 rpm while operating pressurizer pump handle for a minimum of 2 minutes.
(7) Allow excess oil/preservative mixture to drain from port where chip detector (6) was removed. Pour mixture from container into reservoir of pressurizer pump. If reservoir is not full. fill reservoir.
(8)
Re-install chip detector (6) as follows:
(a)
Install packing (5) onto chip detector.
(b)
Install chip detector (6) on C-sump aft scavenge tube (4).
(c)
Torque chip detector to 155-175 lb in. ( 17.5-19.8 N•m).
(d)
method (WP 007 00).
Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire chip detector using the double-strand
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
014 00
GEK 99441
Page7
31 May 2002
(9)
d.
Reconnect coupling nut (2. figure 2). on C-sump oil supply tube (3 ). onto fitting of RTD (I).
(a)
Disconnect pressurizer pump supply hose from coupling nut (2).
(b)
Connect coupling nut (2) to RTD (I). Torque nut to 270-300 lb in. (30.5-33.9 N·m).
Oil-wet (slush) B-sump bearings (see figure 3) as follows:
(I)
Place a suitable container under the B-sump oil supply hose (I) near coupling nut (2).
Lubricating Oil
66
(2)
Disconnect coupling nut (2) from fitting. Allow oil to drain into container.
(3)
Connect pressurizer pump supply hose onto coupling nut (2) on B-sump oil supply hose (I). Tighten cou-
(4)
Reposition container under chip detector (4) located under the lube and scavenge pump at the 6 o'clock
pling nut.
position.
(5) Remove lockwire from chip detector (4). Remove chip detector with packing (3). Remove and discard
packing. Allow any oil to drain into container.
CAUTION
Be careful not to let unwanted objects or material go into
the opening in the accessory drive gearbox (AGB ). Damage
to the AGB can occur.
(6) Remove snapring and cranking pad cover (between fuel control and lube and scavenge pump) on the aft
side of the accessory drive gearbox.
(7)
Connect a 3/8-inch drive extension to a ratchet wrench. Put extension into the 3/8-inch square hole in
gears haft.
NOTE
The handle of pressurizer pump must be operated rapidly
through the full piston stroke so that the proper amount of
oil/preservative mixture is supplied to the B-sump bearings.
(8) Using the ratchet wrench, slowly rotate the gas generator at 5-10 rpm while operating pressurizcr pump
handle for a minimum of 2 minutes.
(9) Allow excess oil/preservative mixture to drain from port where chip detector (4) was removed. Pour mixture from container into reservoir of pressurizer pump. If reservoir is not full, fill reservoir.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
014 00
Page 8
31 May 2002
1.
2.
3.
4.
B-Sump 011 Supply Hose
Coupling Nut
Packing
Chip Detector
I
4-a
1201097-00-A2A
Figure 3.
Oil Wetting (Slushing) of B-Sump Bearings
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
014 00
GEK 99441
31 May 2002
Page 9
(I 0) Re-install chip detector (4) as follows:
(a)
Install packing (3) onto chip detector.
(b)
Install chip detector (4) at the 6 o'clock position under the lube and scavenge pump.
(c)
Torque chip detector to 155-175 lb in. (17 .5-19.8 N•m).
(d)
method (WP 007 00).
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire chip detector using the double-strand
( 11) Reconnect coupling nut (2, figure 3 ), on B-sump oil supply hose (I), onto fitting as follows:
e.
(a)
Disconnect pressurizer pump supply hose from coupling nut (2).
(b)
Connect coupling nut (2) to fitting. Torque nut to 270-300 lb in. (30.5-33.9 N·m).
Oil-wet (slush) A-sump bearings (see figure 4) as follows:
(I)
Place a suitable container under the A-sump oil supply tube (6 ), near coupling nut (5) on the forward end of
the accessory drive gearbox at the 5 o'clock position. forward looking aft.
·
(2)
Disconnect coupling nut (5) from elbow (4). Allow oil to drain into container.
(3)
Connect pressurizer pump supply hose onto coupling nut (5) on A-sump oil supply tube (6). Tighten cou-
(4)
On all models except L32119G06, reposition container under chip detector (3).
pling nut.
(5) On all models except L32119G06, remove lockwire from chip detector (3). Remove chip detector with
packing (2). Remove and discard packing. Allow any oil to drain into container.
NOTE
The handle of pressurizer pump must be operated rapidly
through the full piston stroke so that the proper amount of
oil/preservative mixture is supplied to the A-sump bearings.
(6) Using the ratchet wrench previously connected to a 3/8-drive extension in gearshaft on accessory drive
gearbox. slowly rotate the gas generator at 5-l 0 rpm while operating pressurizer pump handle for a minimum of 2 minutes.
(7) Allow excess oil/preservative mixture to drain from port where chip detector (3) was removed. Pour mixture from container into reservoir of pressurizing pump. If reservoir is not full, fill reservoir.
(8)
On all models except 32119G06, re-install chip detector (3) as follows:
(a)
Install packing (2) onto chip detector.
(b)
Install chip detector (3) onto A-sump scavenge tube (I).
(c)
Torque chip detector to 155-175 lb in. (17 .5-19.8 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
014 00
GEK 99441
Page 10
31 May 2002
ACCESSORY DRIVE
GEARBOX
1. A-SUMP SCAVENGE TUBE
2. PACKING
3. CHIP DETECTOR
4. ELBOW
5. COUPLING NUT
6. A-SUMP OIL SUPPLY TUBE
NOTE: L32119G06 DOES NOT USE
ITEMS 1 THROUGH 3
1201 098-00-A2A
Figure 4.
Oil Wetting (Slushing) of A-Sump Bearings
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
014 00
GEK 99441
Page 11
31 May 2002
(d)
method (WP 007 00).
(9)
Using 0.032 inch (0.81 mm) diameter lockwire, lock-wire chip detector using the double-strand
Reconnect coupling nut (5. figure 4). on A-sump oil supply tube (6). onto elbow (4) as follows:
(a)
Disconnect pressurizer pump supply hose from coupling nut (5).
(b)
Connect coupling nut (5) to elbow (4) on accessory drive gearbox. Torque nut to 270-300 lb in.
(30.5-33.9 N·m).
8.
f.
Remove ratchet wrench and 3/8-inch drive extension from the cranking pad on the aft side of the accessory drive
gearbox.
g.
Install cranking pad cover and snapring.
h.
Reinstall customer equipment that was removed to gain access to AGB cranking pad and to applicable areas of
gas turbine.
1.
Secure and store pressurizer pump (see figure I).
PRESERVATION OF FUEL SYSTEM (MARINE ONLY).
NOTE
•
•
a.
This procedure is to be followed prior to removal of
the gas turbine for shipment or storage.
Only clean, new oil and clean containers must be
used.
Place a suitable container under fuel pump (5, figure 5) to catch fuel drainage.
[ji] k{jt]
Aviation Turbine Fuel (Jet Fuel)
292
b.
Remove lock wire and four bolts (I). Disconnect filter-to-pump hose (2) from fuel-in port (4 ). Do not remove
gasket {3).
c.
Connect a hose from a gravity-fed container (filled with approximately 2 gallons (8 liters) of lubricating oil
MIL-L-6081 (Grade 1010) and filtered through a !O-micron filter) to fuel-in port (4) on fuel pump (5).
d.
Secure gravity-fed hose with four bolts (I). Tighten bolts.
e.
Place power lever in the FULL OPEN position and motor gas turbine with starter for 2 minutes so that a maximum of I gallon (4 liters) of oil will enter fuel pump. Disengage starter and place power level in CLOSED position.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
014 00
31 May 2002
Page 12
1. Bolt {Qty 4)
2. Filter-to-Pump Hose
3. Gasket
4. Fuel-In Port
5. Fuel Pump
7
5
1201099-00-02
Figure 5.
Preservation of Fuel System (Marine Only)
f.
Remove four bolts (I) and disconnect gravity-fed hose from fuel-in port (4) on fuel pump (5 ).
g.
Cover fuel-in port (4) with protective cover. Secure cover and gasket (3) with four bolts (I).
h.
Cover filter-to-pump hose (2) with protective cover.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
015 00
31 May 2002
Page 1 of 6
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL OPERATION
SPECTROMETRIC OIL ANALYSIS PROGRAM (SOAP)
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G01 /-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................ .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Analysis Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Sampling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spectrometric Oil Analysis Program (SOAP) .............................................. .
Support Equipment .................................................................. .
I
4
4
1. INTRODUCTION. This work package provides instructions for determining the internal condition of the gas turbine
oil-wetted components. The maintenance tool to accomplish this is called the Spectrometric Oil Analysis Program (SOAP).
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
None
4.
SPECTROMETRIC OIL ANALYSIS PROGRAM (SOAP).
a.
The Spectrometric Oil Analysis Program (SOAP) is in use as a maintenance tool in determining the internal condition of the gas turbine oil-wetted components. such as bearings. gears, lube pump and related parts. SOAP is used as a supplement to the normal maintenance procedures of chip detector and filter inspection, and does not replace these established
safety checks.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
015 00
31 May 2002
Page2
NOTE
•
•
•
A micron is a measurement equal to one-thousandth
of a millimeter.
The oil filter of the LM500 gas turbine is rated at
25 microns nominal.
The lower limit of naked eye visibility is 40 microns.
b.
As the gas turbine parts are operating, normal wear can be expected on gears. splines, and bearings. This wear
causes metallic particles of microscopic size (less than I micron) to circulate freely within the lubrication system where they
stay in suspension in the oil.
c.
Samples of oil taken from the gas turbine after shutdown will contain varying amounts of wear-metal particles.
The oil sample is analyzed by either a rotating-disk emission spectrometer or an atomic absorption instrument which translates
the analytical information into parts per million (ppm) for the following elements:
AI - Aluminum
Fe - Iron
Cr - Chromium
Ti - Titanium
Aea - Silver
Cu - Copper
Sn Si MoPb Ni MgV -
Tin
Silicon
Molybdenum
Lead
Nickel
Magnesium
Vanadium
d. Wear-metal content is the most important data to evaluate. The wear-metals build up to the normal concentration during the early hours of operation and then level off with no further increase throughout the life of the gas turbine, unless
a discrepancy develops. Minor fluctuations are probably due to contamination during sampling procedures or to addition of
new oil. In gas turbines where abnormal friction is developing, a pattern or trend of increasing wear-metal is critical. A rapid
buildup may indicate imminent component failure. If the rate of wear-metals is slow and steady, there is some point where
friction responsible for wear-metal exceeds normal and becomes abnormal. This critical point is called the "threshold limit".
The threshold limits. or values, have been established by correlation with Disassembly-Inspection Reports, where the actual
condition of gas turbine parts could be compared to the amount and rate of increase of suspended metals in SOAP samples
prior to gas turbine removal and teardown.
e.
The quantity of wear-metal as well as the type of wear-metal present must be evaluated. The type and combination of metals may help to determine which component is failing and to assess how serious it may be. For example, the presence of iron and silver may indicate bearing wear and gear wear. Iron alone may indicate gear wear. Differentiation of main
shaft bearings and gears can only be positively detected by Spectro-Chemical analysis of metal chips because the percentage
of chromium in bearings and nickel in gears is very small (less than 5% ).
f.
Oil samples must be taken at time intervals specified in WP 008 00 and care must be exercised while taking the
sample. External contamination introduced to the oil sample will give a false indication of the exact internal condition of the
gas turbine. The oil sample should always be taken from the same location, and in the same way as directed. to assure that a
representative sample of the gas turbine lube oil will be analyzed. Submit samples to the operator's analysis laboratory, who
will report results of analysis performed including recommended corrective action.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
015 00
GEK 99441
Page3
31 May 2002
g.
Table I lists all major lubrication system components. The following information may he helpful in determining
the source of wear-metals:
•
•
•
Rapid increase in iron is indicative of No. 3 hearing
problem and may indicate a high vibration condition.
High aluminum or combination aluminum/nickel usually indicates a fretting condition between the No. 3
bearing housing and the front frame, and may indicate
a high vibration condition.
High nickel may indicate wear of the No. 3 hearing
antirotation key.
TABLE 1.
Wear-metal
LUBRICATION SYSTEM COMPONENTS
Oil System Component
Fe
Main luhe and scavenge pump gerotors and shaft
Fe. Ni. Cr
Radial drive shaft
Power takeoff assembly gears
Fe. Cr. Ni. Mo
Compressor forward shaft
Fe. Cr. Mo. V
Typical for all main bearing races and balls/rollers
Fe, Ni, Ag Plating
No. 2, 3, 4, 5, 6, and 7 main bearing cages
Fe. Cr Plating
All main bearing rotating oil seals
Fe. Cr. Cu. Ni
No. I. 2. 3. 4. 5. and 6 main bearing stationary oil seals
No. I and 2 main bearing housings
Power takeoff assembly bearing housing
Al. Si
Front frame or accessory gearbox
Main luhe and scavenge pump components
Cu
Main luhe and scavenge pump bearings
Ni. Fe. Mo. Cr Plating
No. 7 main bearing rotating oil seal
Ni. Cr, Fe. Mo
No. 3. 4. 5. and 7 main bearing housings
Ni. Cr, Fe
No. 6 main bearing housing
Ni. Cu. Si. Ag Plating
No. I main bearing cage
Ti.AI,V
Output shaft
Power takeoff assembly bearing housing
No. 7 main bearing stationary oil seal
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
015 00
31 May 2002
5.
Page4
OIL SAMPLING PROCEDURE.
a.
Observe the following precautions when taking oil samples:
(I)
Sample should be taken as soon as possible after shutdown. while oil is still warm and of uniform viscosity.
(2)
Take sample before servicing oil tank.
(3)
Always use clean sample bottles and do not allow any foreign material to come in contact with oil or sam-
pling equipment.
(4) Always take samples from the same location and in the same manner to ensure a representative sample that
is similar to previous samples.
h.
Obtain sample as follows:
Lubricating Oil
(I)
66
Remove tank fill cap and fill port strainer.
(2) Insert sample tube or semi-rigid hose, 18 inches (46 cm) minimum length by 1/2 inch ( 13 mm) diameter,
straight down into tank to lowest point.
(3)
Place thumb over end of tube and withdraw sample from tank.
(4)
Empty contents of tube or hose into a clean sample container.
(5)
Repeat as often as necessary to obtain required sample quantity.
(6)
Discard or clean sample tube. Replace tank fill strainer and cap.
(7)
Tag or label sample bottles with the following information for identification:
•
•
•
•
•
6.
Unit number or location
Gas turbine serial number
Gas turbine operating hours since installation
Date sample obtained
Operator's name.
OIL ANALYSIS INTERPRETATION.
The values of wear-metal content and threshold limit values for these elements in parts per million (ppm) are given in tables 2
or 3, depending upon the laboratory analysis procedure and equipment utilized.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
015 00
GEK 99441
Page 5/6
31 May 2002
TABLE 2.
SPECTROMETRIC ANALYSIS
Fe
Ag
AI
Cr
Cu
Ni
Ti
4
2
2
2
3
3
3
Normal range
0-15
0-3
0-3
0-3
0-10
0-5
0-5
Marginal range
16-18
NIA
NIA
NIA
11-14
6-7
6
High range
19-22
4
4
4
15-17
8-9
7-8
Abnormal
23+
5+
5+
5+
18+
10+
9+
Abnormal trend
(ppm increase
in 10 hours)
Average concentration other elements: Pb=4 Si=l4 Sn=ll Mo=l
TABLE 3.
ATOMIC ABSORPTION ANALYSIS
Fe
Ag
AI
Cr
Cu
Ni
Ti
2
2
2
2
2
2
2
0-5
0-3
0-3
0-3
0-4
0-3
0-2
Marginal range
6
NIA
NIA
NIA
5-6
4
NIA
High range
7
4
4
4
7
5
3
Abnormal
8+
5+
5+
5+
8+
6+
4+
Abnormal trend
(ppm increase
in 10 hours)
Normal range
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
016 00
Page 1 of 4
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
GAS TURBINE EXTERNAL INSPECTION AND SPECIAL INSPECTIONS
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Consumable Materials ................................................................ .
External Inspection of Gas Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Inspections of Gas Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Equipment .................................................................. .
2
I
4
1. INTRODUCTION. This work package provides instructions for periodic external inspection as determined in
WP 008 00. This work package also provides special inspections of gas turbines that have been exposed to fire or fire extinguishing agents.
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Gloves. Thermally Insulated
Local Purchase
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
016 00
31 May 2002
4.
Page2
EXTERNAL INSPECTION OF GAS TURBINE.
a.
Before entering the gas turbine area to inspect the gas turbine, do the following:
(I)
Shut down the gas turbine.
(2)
Deactivate the fire extinguishing system.
I WARNING I
Handling Hot Parts
•
•
•
When handling hot parts. wear approved gloves.
Handling of hot parts with bare hands may cause reddening and blistering of skin, or third-degree bums.
If skin is burned. immerse contacted area in cold
water for I 0 minutes. If pain or blistering persists.
immediately get medical attention.
(3) Allow the gas generator to cool to room temperature. Avoid contact with hot parts: wear thermally insulated gloves. if necessary.
(4) Tag electrical switches "Out-of-Service" to prevent activation. Tag the gas turbine operating controls "Do
Not Operate". to prevent starting during a desired shutdown condition.
b.
Inspect gas turbine inlet (WP 009 00).
c. Inspect gas turbine tubes, hoses, tube/hose fittings, electrical cable assemblies. and electrical connectors for
security, overheating, and damage due to leakage.
d.
Inspect lube and scavenge pump, accessory gearbox, and gearbox mounted accessories for security, damage. and
e.
Inspect ignition exciter (2. figure I). igniter plugs (3 ). and igniter leads (4) for damage. overheating, and
f.
Inspect gas turbine mounts for security and damage.
g.
Check for loose or missing bolts on all flanges.
h.
Inspect variable geometry feedback cable (5) for kinking, abrasion, and separation.
i.
Check clevis pins for looseness and retention of cotter pins.
J
Check actuating shaft and VG control levers for security.
leakage.
security.
k. Inspect variable geometry linkages (7). actuators (6). and hydraulic hoses for security, damage. chafing, missing
clamps, and leaks.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
016 00
GEK 99441
Page3
31 May 2002
4
/
1
1.
2.
3.
4.
Inlet Duct
Ignition Exciter
Igniter Plugs
Igniter Leads
Figure I.
I.
m.
s. Variable Geometry Feedback Cable
6. Variable Geometry Actuators (Two)
1. Variable Geometry linkages
1201100-00-02
Gas Turbine External Inspection
Inspect components of variable stator vanes (VSV) (WP 029 00) for:
(I)
Loose or missing locknuts on inlet guide vanes (IGV) through stage 5 vane levers.
(2)
Wear or looseness in IGV lever spherical bearings.
(3)
Presence of vane actuating arm pins and tabwashers at actuating ring.
(4)
Security of all stages I through 5 vane lever retainers and ring connectors.
(5)
Loose or worn spherical bearings or actuators. arm-to-ring links. VSV actuators, and actuating shafts.
(6)
Presence and condition of plastic washers on either side of actuator mount.
(7)
Security of all actuating arm levers and bearing mounts.
(8)
Bent or deformed vane arms and actuating rings.
(Industrial Only). Inspect (WP 030 00) manifold assembly. fuel feed tubes, and fuel injectors for:
•
•
•
•
Security or damage
Loose. deformed, or missing brackets and clamps
Loose tubing nuts or flange bolts
Broken or missing lock wire.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
016 00
31 May 2002
n.
(Marine Only). Inspect (WP 030 I 0) fuel injector hose assemblies and fuel distributor block assembly for:
•
•
•
•
o.
5.
Page4
Security or damage
Loose, deformed. or missing brackets and clamps
Loose tubing nuts or flange bolts
Broken or missing lockwire.
Inspect (WP 011 00) exhaust duct for cracks, dents. loose fasteners. and security.
SPECIAL INSPECTIONS OF GAS WRBINE.
Refer to table I for special inspections that have to be done when the gas turbine has been exposed to fire or fire extinguishing
agents.
TABLE 1.
Event
SPECIAL INSPECTIONS
Condition
Disposition
Gas Turbine Damaged by Fire
Obvious external or suspected internal
damage.
Gas Turbine Flooded with Fire Extinguishing Agents
a.
C0 2 (Carbon Dioxide).
No action required.
b.
Halogens (external surfaces).
Wash external surfaces.
c.
Others.
Replace gas turbine.
Replace gas turbine.
Gas Turbine Overtemperature
Violation of temperature limits given
in WP005 00.
Replace gas turbine.
Gas Turbine Overspeed
Violation of speed limits given in
WP 005 00.
Replace gas turbine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
017 00
31 May 2002
Page 1 of 8
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
COMPRESSOR AND GAS TURBINE EXTERNAL SURFACES
CLEANING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119G01 /-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Cleaning of Gas Turbine External Surfaces ...............................................
Compressor Cleaning and Rinsing ......................................................
Consumable Materials ................................................................
Introduction ........................................................................
Preparation of Cleaning and Rinse Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Equipment ..................................................................
I.
.
.
.
.
.
.
7
4
2
2
INTRODUCTION.
a.
This work package provides instructions for cleaning (water wash) the compressor and the external surfaces of
the gas turbine. The compressor must be cleaned before preservation, when gas turbine performance is low, and when visual
or borescope inspection shows a buildup of carbon, dirt. or oily deposits on compressor blades or vanes.
b.
The compressor cleaning procedure consists of spraying water-wash solution into the inlet of the gas turbine, letting the solution soak. and then rinsing with rinse solution. If compressor contamination is severe and there is only little performance improvement. it may be necessary to repeat the cleaning procedure.
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
Equipment, Steam Cleaning
Hose. Flexible (with Adjustable Spray Nozzle)
2C5952GOI
Unit, Compressor Cleaning Pumping
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
017 00
GEK 99441
Page2
31 May 2002
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
AlcohoL Isopropyl (TT-1-735)
Local Purchase
Brush, Soft-Bristle
Local Purchase
Cleaner, B&B 3100
B&B Chemical Co., Inc.
P.O. Box 796
Miami. FL 33166
USA
Cleaner. Rivenaes R-MC
STS West
18502 Laurel Park Road
Compton, CA 90220
USA
or
STS Southeast
507 Industrial Way
Boynton Beach, FL 33426
USA
or
STS Middle Atlantic
155 South Limerick Road
Limerick. PA 19468
USA
or
IVAR Rivanaes A/S
Damsgardsveien 35
500 Bergen
Norway
Methanol (0-M-232)
4.
Local Purchase
PREPARATION OF CLEANING AND RINSE SOLUTIONS.
a.
Rivenaes R-MC and B&B 3100 are the only cleaners approved for use on the LM500 gas turbine.
b.
If Rivenaes R-MC will be used, refer to table I for preparing the cleaning and rinse solutions to use at various
temperatures.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
017 00
GEK 99441
Page 3
31 May 2002
c.
If B&B 3100 will be used. refer to table 2 for preparing the cleaning and rinse solutions to use at various
temperatures.
TABLE 1.
Temperature
RIVENAES R-MC CLEANING AND RINSE SOLUTIONS
Cleaning Solution
Rinse Solution
[p''i?l
[ji)
R-MC or Rivenaes R-MC
Cleaner/Mixture
403
Isopropyl Alcohol, TT-1-735
Methanol, 0-M-232
11
83
NOTE
•
•
Rinsing of the gas turbine with Rivenaes R-MC is optional if drying cycling is
performed.
Rivenaes R-MC is supplied from the manufacturer ready to use. No further
dilution is necessary.
1007c R-MC
Fresh water.
23°F to 41°F
(-5°C to +5°C)
Four parts R-MC; one part isopropyl
alcohol or methanol.
Three parts fresh water; two parts isopropyl alcohol or methanol.
-6°F to +23°F
(-21 oc to -5°C)
Three parts R-MC; two parts isopropyl
alcohol or methanol.
Three parts fresh water; two parts isopropyl alcohol or methanol.
Do not wash: solution will freeze.
Do not rinse; solution will freeze.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
017 00
31 May 2002
Page 4
TABLE 2.
Temperature
B&B 3100 CLEANING AND RINSE SOLUTIONS
Rinse Solution
Cleaning Solution
8&8 3100 Cleaner-Water Solution
18
Isopropyl Alcohol, TT-1-735
11
83
Methanol, 0-M-232
l4°F to 40°F
( -10°C to +4 °C)
5.
One part cleaner; four parts fresh
water.
Fresh water.
One part cleaner; 2-1/2 parts isopropyl
alcohol or methanol; 1-1/2 parts fresh
water.
Two parts fresh water; three parts isopropyl alcohol or methanol.
Do not wash; solution will freeze.
Do not rinse; solution will freeze.
COMPRESSOR CLEANING AND RINSING.
CAUTION
The gas turbine must he allowed to cool to 320°F ( 160°C)
or less before cleaning the inlet airflow area (see tigure I).
a.
Using a soft-bristle brush soaked with the cleaning solution, clean the inlet airflow area.
b.
Using a soft-bristle brush soaked with the rinse solution. rinse the inlet airtlow area.
c.
Connect the inlet hose (6) of compressor cleaning pumping unit 2C5952GOI (5) to inlet tee (7) at the 6 o'clock
position under the front frame (8). Tighten coupling nut on inlet hose to 5-10 lb in. (0.6-1.1 N·m).
d.
Using the cleaning solution, clean compressor section as follows:
(I)
Place the suction hose (3) of the pumping unit (5) into container with the cleaning solution.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
017 00
31 May 2002
Page 5
1. Start Switch
2. Stop Switch
3. Suction Hose
4. Electrical Cable
5. Compressor Cleaning Pumping
Unit 2C5952GC1
6. -Inlet Hose
7. Inlet Tee
8. Front Frame
NOTE
I
WATER WASH MANIFOLD
HOSE ASSEMBLY (QTY 8)
TKE WATER WASH MANIFOLD HOSE
ASSEMBLIES ARE LOCATED AROUND
THE CIRCUMFERENCE ON THE FRONT
FRAME.
1201101-00-A2A
Figure I.
Compressor Cleaning and Rinsing
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
017 00
GEK 99441
Page6
31 May 2002
CAUTION
•
•
•
•
Do not clean the compressor while the gas turbine is
operating. Compressor temperatures at operating
speed may cause the compressor casing to warp, causing blade rubs.
The gas turbine must be allowed to cool to 320°F
( 160oC) or less before cleaning the compressor
section.
Do not exceed starter duty cycles. Observe required
starter cooling intervals between cleaning cycles.
Do not allow the cleaning solution into compressor
until a motoring speed of 24-28CJr of power turbine
shaft speed is reached.
NOTE
The motoring speed will decrease as the cleaning solution is
ingested into gas turbine.
(2)
Motor gas turbine to 24-28% of power turbine shaft speed.
(3)
Push the start switch (I) on pumping unit (5 ). Adjust the pumping unit pressure so that the cleaning solution enters the compressor at a rate of 2-3 gallons per minute (8-11 liters per minute) and at 35-40 psig (241-276 kPa). Continue to motor the gas turbine for 35-40 seconds; do not exceed starter duty cycles.
(4) Check the solution exiting the exhaust end of gas turbine, to be sure that the solution is clean. If not clean.
repeat the cleaning cycle.
I CAUTioN: I
Stop the operation of the pumping unit (5) before stopping
the motoring of the gas turbine: otherwise. damage to gas
turbine will occur.
(5)
Using the stop switch (2) on the pumping unit (5). stop operation of the pumping unit while still motoring
(6)
Stop motoring the gas turbine and allow the starter to cool for a minimum of 5 minutes.
gas turbine.
e.
f.
ing unit (5 ).
Using the rinse solution. rinse the compressor as follows:
(I)
Remove the suction hose (3) of the pumping unit (5) from container with the cleaning solution.
(2)
Place the suction hose (3) into container with the rinse solution.
(3)
Using instructions in steps d.(2) through d.(6). rinse the compressor.
Remove suction hose (3) from the rinse solution. Disconnect inlet hose (6) from inlet tee (7). Store the pump-
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
017 00
GEK 99441
31 May 2002
g.
Dry the gas turbine as follows:
(I)
(2)
than 2 minutes.
6.
Page7
Start the gas turbine.
Slowly accelerate the gas turbine to 851ff power turbine shaft speed. and remain at this setting for no more
(3)
Slowly decrease gas turbine speed to IDLE. Remain at IDLE for a minimum of 2 minutes.
(4)
Shut down the gas turbine.
CLEANING OF GAS TIJRBINE EXTERNAL SURFACES.
a.
If the external surfaces of the gas turbine (especially the variable stator vane system) have excessive dirt buildup.
wash the external surfaces using the following:
•
•
•
b.
50 to 60 gallons (190 to 227 liters) of clean potable water
Flexible hose with adjustable spray nozzle
Water pressure of 40-45 psi (276-31 0 kPa).
If the water will not remove the dirt. do the following:
I WARNING I
Steam Cleaning
•
•
•
( 1)
Hot steam can burn exposed tissue. Dry material
removed by steam spray can injure eyes.
If dry material contacts eyes, flush affected area thoroughly with water. If steam contacts skin or eyes.
immerse affected area in cold water for 10 minutes. If
blistering occurs. immediately get medical help.
When steam-cleaning. wear approved gloves, apron,
and face shield.
If steam cleaning equipment is available, steam-clean gas turbine.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
017 00
31 May 2002
(2)
Page 8
If steam cleaning equipment is not available. do the following:
R-MC or Rivenaes R-MC
Cleaner/Mixture
B&B 3100 Cleaner-Water Solution
403
18
(a) Spray the cleaning solution (refer to table I or 2 for mixture) onto gas turbine. Allow the cleaning
solution to soak for a minimum of 15 minutes.
(b)
(3)
Spray the rinse solution (refer to table I or 2 for mixture) onto gas turbine.
Start the gas turbine and operate at IDLE speed for a minimum of 5 minutes to dry excessive water.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
018 00
31 May 2002
Page 1/2
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
IGNITION SYSTEM TEST
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Consumable Materials ................................................................
Ignition System Test .................................................................
Introduction ........................................................................
Support Equipment ..................................................................
1.
INTRODUCTION. This work package provides instructions for testing the two igniter plugs.
2.
SUPPORT EQUIPMENT. None
3.
CONSUMABLE MATERIALS. None
4.
IGNITION SYSTEM lEST.
a.
Select switch to energize one igniter plug.
b.
Start the gas turbine.
Page No.
.
.
.
.
c.
If the gas turbine starts. shut down. If the gas turbine does not start. test the other igniter plug before taking corrective action.
d.
Select switch to energize the other igniter plug.
e.
Start the gas turbine.
f.
If the gas turbine starts on both igniter plugs. the test is complete. Return switch to normal position.
g.
If the gas turbine starts on one igniter plug, but not the other, replace the suspect igniter plug (WP 023 00) and
repeat the test.
h. If the gas turbine does not start. troubleshoot (WP 006 00 for Industrial Gas Turbine or WP 006 I 0 for Marine
Gas Turbine).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
019 00
GEK 99441
31 May 2002
Page 1 of 12
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
LUBRICATION SYSTEM
SERVICING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ......................................................... : . .....
Introduction ........................................................................
Servicing
A-Sump Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lube and Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lube Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Equipment ..................................................................
1.
.
.
2
.
.
.
.
8
8
2
INTRODUCTION.
a.
This work package provides instructions for servicing the lubrication system as determined hy the periodic
inspections and maintenance table in WP 008 00.
h.
The lubrication system must be serviced on a scheduled basis, when the gas turbine performance has deteriorated. or when inspection reveals that dirt or foreign material has built up in the oil system or its components.
c.
The lubrication system can become contaminated hy metal, fuel. or water. Oil samples must be taken and tested
for contamination as instructed in WP 015 00 (Spectrometric Oil Analysis).
2.
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
2C5615GOI
Wrench. Lube Pump Insert
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
3.
Page2
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
4.
Description
Manufacturer
Lockwire. 0.()32 inch (0.81 mm) diameter
Local Purchase
Oil, Lubricating
(MIL-L-7808 or MIL-L-23699)
Local Purchase
SERVICING OF LUBE FILTER.
a.
Remove lock wire from lube filter (I, figure I) or filter assembly for configuration L32119G05/-G06.
Lubricating Oil
66
NOTE
The lube and scavenge pump insert (2) may loosen when
unthreading the lube filter (I) or filter carrier assembly for
configuration L32119G05/-G06.
b.
For configuration L32119GO l/-G02/-G03/-G04. unthread and remove lube filter
pump (3 ). If insert (2) is loose. hand-tighten.
(I)
from lube and scavenge
For configuration L32119G05/-G06. unthread and remove filter carrier assembly from lube and scavenge
c.
pump (3). If insert (2) is loose, hand-tighten insert.
d.
For configuration L32119GO l/-G02/-G03/-G04. remove and discard preformed packings (4 and 5) from lube
e.
For configuration L32119G05/-G06, remove and discard preformed packings (4 and 6) from filter carrier assem-
filter (I).
bly.
f.
For configuration L32119G05/-G06. remove filter element (7) from filter carrier assembly. Remove and discard
preformed packing (8).
g.
Inspect lube filter and filter carrier assembly as instructed in table I.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
019 00
GEK 99441
Page3
31 May 2002
LEGEND:
1. LUBE FILTER
2. LUBE AND SCAVENGE
PUMP INSERT
3. LUBE AND SCAVENGE
L32119G 01/-G 02/-G03/-G 04
PUMP
4. PREFORMED PACKING - - - - - - - - - - - - - - - - - - - - - - - - 5. PREFORMED PACKING
6. PREFORMED PACKING
7. FILTER ELEMENT
8. PREFORMED PACKING
9. PREFORMED PACKING
FILTER CARRIER
ASSEMBLY
L32119G05/-G06
1203196-00-A2A
Figure I.
Removal and Installation of Lubc Filter
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
Page 4
TABLE 1.
Inspect
a.
INSPECTION OF LUBE FILTER
Usable Limits
Max Repairable Limits
Corrective Action
Body of lube filter and
filter carrier assembly
(see figure 2) for:
(I) Cracks.
None allowed.
Not repairable.
Replace lube filter or filter
carrier assembly.
(2) Stripped threads.
One missing thread. without high metal.
Not repairable.
Replace lube filter or filter
carrier assembly.
(a) Packing
grooves.
Any number, 0.005 inch
(0.13 mm) deep. without
high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
(b) Body.
Any number. 0.010 inch
(0.25 mm) deep, without
high metal.
Same as usable limits. with
high metal.
.Remove high metal
(WP 007 00).
Up to three broken holes.
Not repairable.
Replace lube filter.
(I) Holes.
None allowed.
Not repairable.
Replace lube filter for configurations L32119GO I I
-G021-G031-G04. Replace
filter element for configurations L32119G051-G06.
(2) Nicks, dents, and
Any number. 0.010 inch
(0.25 mm) deep. without
high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
Not allowed.
Not repairable.
Replace lube filter for configurations L32119GO II
-G021-G031-G04 or replace
filter element for configurations L32119G051-G06.
Remove. inspect. and reinstall chip detectors
(WP 013 00). Service the
lube and scavenge pump
(para 5 ). Service the Asump scavenge pump for
configurations L32119GO II
-G021-G031-G041-G05
(para 5).
(3) Nicks. dents. and
scratches in:
( 4) Broken lock wire
holes.
b.
Filter element for:
scratches at end.
(3) Contamination
(metallic fuzz or
chips).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
Pages
METALLIC
FUZZ
METALLIC
CHIPS
PACKING
GROOVE
THREADS
L32119G 01/-G 02/-G03/-G04
1203197-00-A2A
Figure 2.
Inspection of Lube Filler (Sheet I of 2)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
Page6
I
I
I
I
I
I
I
METALLIC
I
THREADS
PACKING
GROOVE
FUZZ
METALLIC_
CHIPS
Q
I
L32119G05/-G06
1203198-00-A2A
Figure 2.
Inspection of Lube Filter (Sheet 2 of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
h.
Page7
Install lube filter (I. figure I) or filter carrier assembly for configurations L32119G05/-G06, as follows:
Lubricating Oil
(I)
66
Lubricate all preformed packings and packing grooves with a light coat of lubricating oil MIL-L-7808 or
MIL-L23699.
(2)
For configurations L32119GOI/-G02/-G03/-G04, install packings (4 and 5) on lube filter (I).
(3)
For configurations L32119G05/-G06, do the following:
(4)
(a)
Install preformed packing (8) on filter carrier assembly.
(b)
Install filter element (7) on filter carrier assembly.
(c)
Install preformed packings (4 and 6) on filter carrier assembly.
Before installing lube filter (I) or filter carrier assembly for configurations L32119G05/-G06, do the
following:
(a)
Using a flashlight, inspect the port cavity of pump (3 ), to be sure that the port is clean.
(b) Inspect the port cavity of pump (3) for burrs and high metal that may damage the preformed packings
on lube filter (I) or filter carrier assembly for configurations L32119G05/-G06. Remove any burrs or high metal (WP 007 00)
from port cavity and lead-in chamfer.
CAUTION
The lube and scavenge pump insert (2) must be checked for
looseness before installing lube filter (I) or filter carrier
assembly for configurations L32119G05/-G06: otherwise.
leaks will occur.
(c) Check insert (2) for looseness and for leakage indications. If insert is loose or if there is indication of
leakage around insert. do the following:
I
Using lube pump insert wrench 2C5615GOI. remove insert (2) from pump (3).
2
Remove and discard preformed packing (9) from insert (2).
Lubricating Oil
3
66
Using a light coat of lubricating oil MIL-L-7808 or MIL-L-23699. lubricate new preformed
packing (9).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
PageS
4
Install new preformed packing (9) onto insert (2).
5
Install insert (2) into pump (3 ).
6
Using wrench 2C5615GOI. torque insert (2) to 480-500 lb in. (54.2-56.5 N·m).
I CAUTION I
•
•
For configurations L32119GO I /-G02/-G03/-G04, be
careful not to damage preformed packings (4 and 5)
when installing lube filter (I) into pump (3) or leaks
will occur.
For configurations L32119G05/-G06. be careful not
to damage preformed packings (4 and 6) when installing filter carrier assembly into pump (3) or leaks will
occur.
(5) For configurations L32119GO I /-G02/-G03/-G04. installlube filter (I) into port of pump (3 ). Torque lube
filter to 150-200 lb in. (16.9-22.6 N·m).
(6) For configurations L32119G05/-G06, install filter carrier assembly into port of pump (3 ). Torque filter
carrier assembly to 150-200 lb in. ( 16.9- 22.6 N·m).
(7)
Using 0.032 inch (0.81 mm) diameter lock wire. lock-wire Iube filter (I) using the double-strand method
(WP 007 00).
5.
SERVICING OF LUBE AND SCAVENGE PUMP AND A-SUMP SCAVENGE PUMP.
a.
Using instructions in WP 031 00 or SWP 031 I0. do the following:
NOTE
The following maintenance must be done only when there is
evidence of contamination on the chip detectors or lube
filter element.
(I)
Remove lube and scavenge pump (I, figure 3) to gain access to scavenge screens (2).
(2) For configurations L32119GOI/-G02/-G03/-G04. remove screen insert elbow (3), screen insert nipples (4
and 5 ), screen insert bulkhead tee (6), and scavenge screens (2) from pump (I).
(3)
For configurations L32119G05/-G06, remove screen insert tube nipples (7 and 8). screen insert nipple (4 ).
screen insert bulkhead tee (6). and scavenge screens (2).
(4)
Place a tag on each part. and identify each part as shown in table 2.
(5) For configurations L32119GO I /-G02/-G03/-G04/-G05. remove screen insert elbows (9 and I0) from
A-sump scavenge pump ( 11 ).
(6)
Place a tag on each elbow. and identify each elbow as shown in table 2.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
Page 9
TABLE 2.
SCREEN INSERTS AND SCAVENGE SCREENS IDENTIFICATION
Part
Identi1ication/Location
L32119GO I/-G02/-G03/-G04/-G05
90° Screen Insert Elbow (9)
A-Sump Scavenge (A-Sump Scavenge Pump)
45o Screen Insert Elbow (10)
Forward Bearing Sump Scavenge (A-Sump Scavenge
Pump)
L32119GO I/-G02/-G03/-G04
Screen Insert Nipple (4)
C-Sump Aft Scavenge (Luhe and Scavenge Pump)
90° Screen Insert El how (3)
C-Sump Forward Scavenge (Luhe and Scavenge Pump)
Screen Insert Nipple (5)
B-Sump Forward Scavenge (Luhe and Scavenge Pump)
Screen Insert Bulkhead Tee (6)
B-Sump Aft Scavenge (Luhe and Scavenge Pump)
Scavenge Screens (2)
Accessory Drive Gearbox Assembly (Luhe and Scavenge
Pump)
L32119G05/-G06
Screen Insert Tu he Nipple (8)
B-Sump Forward Scavenge (Luhe and Scavenge Pump)
Screen Insert Tube Nipple (7)
Oil Scavenge Tube (Luhe and Scavenge Pump)
Screen Insert Bulkhead Tee (6)
B-Sump Aft Scavenge (Luhe and Scavenge Pump)
Scavenge Screens (2)
Accessory Drive Gearbox Assembly (Luhe and Scavenge
Pump)
Screen Insert Nipple (4)
C-Sump Aft Scavenge (Luhe and Scavenge Pump)
h.
Visually inspect each screen for contamination. If there is contamination, analyze and identify contaminants,
removed from screens, to determine the source as follows:
NOTE
•
•
Bearing races, rollers, and halls are magnetic; therefore, separating the magnetic contaminant will help to
identify the source.
Failure of the main gas turbine hearings requires
replacement of the gas generator or the power turbine.
or both.
(I) If the contaminant is identified as hearing material (such as rollers. halls. or race fragments), replace the
gas generator or the power turbine, or both.
(2) Because main gas turbine hearing distress also increases luhe scavenge temperatures and gas turbine vibrations. review the log sheets for significant changes in gas turbine operating parameters.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
019 00
GEK 99441
Page 10
31 May 2002
L32119G01/-G02/-G03/-G04
LEGEND:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
LUBE AND SCAVENGE PUMP
SCAVENGE SCREENS
SCREEN INSERT ELBOW
SCREEN INSERT NIPPLE
SCREEN INSERT NIPPLE
SCREEN INSERT BULKHEAD TEE
SCREEN INSERT TUBE NIPPLE
SCREEN INSERT TUBE NIPPLE
SCREEN INSERT ELBOW
SCREEN INSERT ELBOW
A-SUMP SCAVENGE PUMP
1203199-00-A2A
Figure 3.
Servicing of Lube and Scavenge Pump, and A-Sump Scavenge Pump (Sheet I of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
019 00
GEK 99441
Page 11
31 May 2002
VIEW AFT LOOKING FORWARD
L32119G05/-G06
L32119G01/-G02/-G03/-G04/-G05
1203200-00-A2A
Figure 3.
Servicing of Lube and Scavenge Pump, and A-Sump Scavenge Pump (Sheet 2 of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
019 00
31 May 2002
(3)
Page 12
If the contaminant is identified as a fragment of a bolt or rivet, replace component as indicated by screen
identity.
(4) If the contaminant is identified as pieces of packings. gasket, lock wire, debris of coked oil. machining
chips, or seal rub strip material. do the following:
(a)
Monitor the gas turbine for lube scavenge temperature and turbine vibrations.
(b) Inspect and clean the parts. listed in table 2, daily. Monitor lubrication system parameters until problem is found. or until the screens are found clean for two successive days: then resume normal inspection intervals.
c.
Using instructions in WP 031 00 or SWP 031 I 0. clean and inspect parts listed in table 2.
d.
Using instructions in WP 031 00 or SWP 031 I 0. re-install the following:
(I)
For configurations L32119GO I /-G02/-G03/-G04, install the screen insert elbow (3, figure 3 ), screen insert
nipples (4 and 5 ). the screen insert bulkhead tee (6 ), and scavenge screens (2) into lube and scavenge pump (I) at locations
identified in table 2.
(2) For configurations L32119G05/-G06, install screen insert tube nipples (4. 7 and 8). screen insert bulkhead
tee (6). and scavenge screens (2) into lube and scavenge pump (I) at locations identified in table 2.
(3)
Installlube and scavenge pump (I).
(4) For configurations L32119GO I /-G02/-G03/-G04/-G05. install screen insert elbows (9 and I 0) into A-sump
scavenge pump ( 11) at locations identified in table 2.
(5)
Remove all tags.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
020 00
31 May 2002
Page 1 of 10
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
FUEL SYSTEM
SERVICING
(LEVEL 1 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
MARINE GAS TURBINE
Alphabetical Index
Subject
Page No.
Cleaning of Fuel System When Contaminated with Water. ...................................
Consumable Materials ......................................................... ." ......
Introduction ........................................................................
Servicing of Fuel System When Bypass Indicator Button has Popped ...........................
Support Equipment ..................................................................
.
.
.
.
.
9
2
1. INTRODUCTION. This work package provides instructions for servicing the fuel system when the bypass indicator
button on fuel filter assembly has popped or when the fuel system is contaminated with water.
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Brush. Soft-Bristle
Local Purchase
Cloth. Lint-Free
Local Purchase
FueL Type NATO-F-75 (MIL-F-1688A)
Local Purchase
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
020 00
GEK 99441
31 May 2002
Page2
Consumable Materials (Cont)
4.
Description
Manufacturer
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
Petrolatum. Corrosion Preventive Compound
(MIL-C-11796)
Local Purchase
Solvent. Dry Cleaning (Stoddard Solvent)
(P-D-680)
Local Purchase
SERVICING OF FUEL SYSTEM WHEN BYPASS INDICATOR BUTTON HAS POPPED.
NOTE
The fuel filter assembly (7. figure I) must be serviced
when the delta P exceeds 16 psid ( 110 kPad). or when
dirt or foreign material is found in the filter element (2).
Also. a popped bypass indicator button indicates a
contaminated filter element.
a.
Remove filter element (2, figure I) as follows:
( 1)
Remove lock wire from bowl ( 1).
Aviation Turbine Fuel (Jet Fuel)
292
I CAUTION I
Use a suitable container to catch fuel when bowl (I) is
removed.
(2)
Remove bowl (1) from head (5).
CAUTION
•
Do not attempt to remove filter element (2) from bowl
(I) by prying on end cap of element. End cap is con-
•
structed of a brittle nylon material which may crack if
this is done.
Filter element is easily damaged. Use care to avoid
damage due to handling.
(3) Remove filter element (2) from bowl (I). If element is difficult to remove. apply fuel to sealing surface at
bottom of bowl and use a twisting motion to free element.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
020 00
GEK 99441
Page3
31 May 2002
3
1. Bovl
2. Ftlter Ele.ent
3. Pack1ng
4. Packtng
5. Head
6. Plug
7. Fuel F11ter Asse.bly
1201104-00-A2A
Figure I.
Removal and Installation of Bowl and Filter Element
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
020 00
GEK 99441
31 May 2002
(4)
h.
Page 4
Remove and discard packing (3) and two packings (4 ).
Inspect filter element (2) for cuts. tears. and contamination and do the following:
(I)
If filter element is damaged. replace filter element.
NOTE
Filter element (2) is not cleanable.
(2)
If filter element (2) is contaminated, do the following:
(a)
Replace filter element.
(h)
Clean and inspect the head (step c) and the bowl (step d).
(c)
Remove and inspect (WP 030 10) the following components:
• Main fuel pump
• Fuel distributor block and fuel distributor
• Fuel injector hose assemblies.
(d)
Using applicable manuals, remove and inspect the following customer's components:
•
•
•
•
c.
No. I and No. 2 fuel shutoff valves
Fuel metering valve
Fuel pressurizing valve
Fuel/Oil cooler.
Clean the head (5, figure I) as follows:
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
(I)
Using a soft-bristle brush soaked with dry cleaning solvent P-D-680, clean the inside of fuel filter head to
remove dirt. Be sure to clean the inlet and outlet ports.
(2)
Using a lint-free cloth, wipe fuel filter head until dry.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
020 00
GEK 99441
31 May 2002
d.
Page 5
Clean bowl (I) as follows:
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
(I)
Immerse bowl in a container with dry cleaning solvent P-D-680.
(2)
Using a soft-bristle brush. clean bowl to remove dirt from the inside and outside surfaces.
I WARNING I
Compressed Air
•
•
•
•
(3)
e.
Using dry, filtered compressed air. dry bowl.
Inspect the head and bowl (refer to table I).
TABLE 1.
Inspect
a.
When using compressed air for any cooling. cleaning,
or drying operation. do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench. wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench, wear approved respirator and goggles.
INSPECTION OF FUEL FILTER HEAD AND BOWL
Usable Limits
Max Repairable Limits
Corrective Action
Bowl (see figure 2,
view A) for:
(I) Cracks.
None allowed.
Not repairable.
Replace bowl.
(2) Contamination.
No foreign material allowed
inside the bowl.
Any amount.
Clean bowl.
(3) Nicks, burrs. and
None allowed.
Not repairable.
Replace bowl.
scratches on
sealing surfaces
and packing
groove.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
020 00
31 May 2002
Page 6
TABLE 1.
Inspect
(4) Nicks, burrs, and
scratches on all
other surfaces.
INSPECTION OF FUEL FILTER HEAD AND BOWL (Cont)
Usable Limits
Any number, 1/32 inch
(0.8 mm) deep, without high
metal.
Max Repairable Limits
Same as usable limits. with
high metal.
Corrective Action
Remove (WP 007 00)
high metal and blend to
adjacent controur.
Refinish defective area
with Alodine 1200
(WP 007 00).
(5) Wear at:
NOTE
If Alodine 1200 coating from a previous inspection is still
intact (not worn away). no further inspection is required.
b.
(a) Area A.
Any amount up to 0.040 inch
(1.02 mm).
Any amount.
Refinish defective area
with Alodine 1200
(WP 007 00).
(b) Area B.
Any amount up to 0.045 inch
(1.14 mm).
Any amount.
Refinish defective area
with Alodine 1200
(WP 007 00).
(I) Nicks, burrs. and
scratches on
sealing surface.
None allowed.
Not repairable.
Replace fuel filter bowl
and head (WP 030 I 0).
(2) Nicks. burrs, and
scratches on all
other surfaces.
Any number, 1/32 inch
(0.8 mm) deep, without
high metal.
Same as usable limits,
with high metal.
Remove (WP 007 00)
high metal and blend to
adjacent contour.
Refinish defective area
with Alodine 1200
(WP 007 00).
(3) Damaged insert.
One full thread missing or
damaged with no high metal
if normal installation with
mating part can be made.
Not repairable.
Replace bowl and head
(WP 030 10).
(4) Cracked. bent.
or broken pins
in electrical
connector.
None allowed.
Not repairable.
Replace bowl and head
(WP030 10).
Head (view B) for:
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
020 00
31 May 2002
Page 7
TABLE 1.
INSPECTION OF FUEL FILTER HEAD AND BOWL (Cont)
Inspect
Usable Limits
(5) Damaged
electrical
connector
housing due to
impact or
excessive side
loads.
There must be no evidence of
dents. The housing must be
parallel to the axis of the filter
assembly.
f.
Max Repairable Limits
Not repairable.
Corrective Action
Replace bowl and head
(WP030 10).
Install filter element (2. figure I) and bowl (I) as follows:
I CAUTION I
Filter element (2) is easily damaged. Use care to avoid
damage due to handling.
(I)
Install two packings (4) in filter element (2).
(2) If necessary. reset bypass indicator button by removing plug (6) and pushing the lever inside the head (5)
towards the centerline of gas turbine. and at the same time push the red indicator button at the aft end of head. Hand-tighten
plug.
(3)
Install filter element (2) into bowl (I).
Corrosion Preventive
Compound, Petrolatum,
Hot Application,
MIL-C-11796
69
(4) Using petrolatum corrosion preventive compound MIL-C-11796. or equivalent, lubricate packing (3 ).
Install packing into packing groove of bowl (I).
NOTE
Lock wire has to be inserted in hole of bowl (I) before bowl
is threaded all the way into head (5 ).
(5)
Insert 0.032 inch (0.81 mm) diameter lock wire in hole of bowl (I). Thread bowl into head (5 ). Hand-
tighten bowl.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
020 00
Page 8
31 May 2002
A
AREA A
'
0.040 INOI
(1.02 •>
SECTION A-A
VIEW A
B
SECTION B-B
VIEWS
1201105-00-A2A
Figure 2.
Inspection of Fuel Filter Head and Bowl
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
020 00
31 May 2002
(6)
Page 9/10
Torque bowl to 200-250 lb in. (22.6-28.2 N·m).
(7)
Using previously installed 0.032 inch (0.81 mm) diameter lockwirc. lock-wire bowl using the doublestrand method (WP 007 00).
5.
CLEANING OF FUEL SYSTEM WHEN CONTAMINATED WITH WATER.
a.
If the fuel system has been contaminated for less than 3 hours. tlush the system with clean fuel as follows:
(I)
Start gas turbine and stabilize at idle for 3 minutes.
(2)
Slow accel to max and monitor T4.8.
(3)
Slow decel to idle.
(4)
Slow accel to max and stabilize for 2 minutes.
(5)
Slow decel to idle.
(6)
Slow accel to max and stabilize for 2 minutes.
(7)
Chop to idle and stabilize for 2 minutes.
(8)
Shut down gas turbine.
h. If the fuel system has been contaminated for more than 3 hours, or if the time period of contamination is not
known. do the following:
(I)
Remove and inspect (WP 030 I 0) the following components:
•
•
•
(2)
Main fuel pump
Fuel distributor block and fuel distributor
Fuel injector hose assemblies.
Using applicable manuals, remove and inspect the following customer's components:
•
•
•
•
No. I and No. 2 fuel shutoff valves
Fuel metering valve
Fuel pressurizing valve
Fuel/Oil cooler.
(3)
Service fuel filter assembly (para 4 ).
(4)
Flush fuel system (step a).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 1 of 20
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
SEAL PRESSURIZING SYSTEM COMPONENTS
REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
(LEVEL 2 MAINTENANCE)
Effectivity:
L32119G02
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
A-Sump Pressure Valve Air Metal Tube
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.........................................................................
C-Sump Aft Tube
Cleaning.........................................................................
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.........................................................................
C-Sump Forward Tube
Cleaning.........................................................................
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.........................................................................
Consumable Materials........................................................... . . . . . .
Drain Separator Tube
Cleaning................................................................... . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Test......................................................................
Removal.........................................................................
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Regulating Valve Assembly
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal.........................................................................
Test.............................................................................
Page No.
I0
10
8
12
7
10
I0
3
12
3
10
I0
6
12
6
2
10
I0
7
12
7
2
19
13
13
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 2
Alphabetical Index (Cant)
Subject
Page No.
Stage 7 Air Tube
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Re1noval ........................................................................
Stage 7 Balance Piston Air Tube
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
Support Equipment ..................................................................
.
.
.
.
.
10
10
5
12
5
.
.
.
.
.
.
10
10
9
12
9
2
1. INTRODUCTION. This work package provides instructions for removing, cleaning. inspecting. and installing the seal
pressurizing system components.
2.
SUPPORT EQUIPMENT.
Support Equipment
3.
Part No.
Nomenclature
21C5536
Kit Adapter (for testing the pressure regulating valve
assembly)
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Brush. Soft-Bristle
Local Purchase
Caps. Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Cloth. Lint-Free
Local Purchase
Filter, 10-Micron
Local Purchase
Fluid. Calibrating (MIL-C-7024)
Local Purchase
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
Page3
31 May 2002
Consumable Materials (Cont)
4.
Description
Manufacturer
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
OiL Lubricating
(MIL-L-7808 or MIL-L-23699)
Local Purchase
OiL Penetrating (VV-P-216)
Local Purchase
Plugs. Protective
Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Solvent. Dry Cleaning (P-D-680)
Local Purchase
C-SUMP AFT TUBE.
a.
Remove C-sump aft tube (I. figure I) as follows:
(I)
Remove bolt (3) and nut (4) that secure cushioned clamp (7) to bracket (32) on exhaust frame.
(2)
Remove bolt (3) that secures cushioned clamp (7) to bracket (33) on low-pressure turbine (LPT) casing.
(3)
forward tube (2).
(4)
b.
Using two wrenches. disconnect coupling nuts on tube (I) from fitting on exhaust frame and from C-sump
Remove tube (I). Remove two cushioned clamps (7) from tube.
Install C-sump aft tube (I) as follows:
(I)
Install and position two cushioned clamps (7) onto tube (I) at locations shown.
(2) Connect coupling nuts on tube (I). to fitting at the 12 o ·clock position on exhaust frame and to C-sump forward tube (2). Hand-tighten coupling nuts.
(3) Using bolt (3) and nut (4). secure cushioned clamp (7) to bracket (32) on exhaust frame. Torque nut to
38-42 lb in. (4.3-4.7 N·m).
(4)
(4.3-4.7 N·m).
(5)
Using bolt (3), secure cushioned clamp (7) to bracket (33) on LPT casing. Torque bolt to 38-42lb in.
Torque coupling nuts on tube (I) to 270-300 lb in. (30.5-33.9 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
Page4
31 May 2002
3--'1
\
1
,
I
...... ....,
'
38
I
I
........ _...
I•
.. __
I
I
I
I
........
t
I
I
I
-J
1. C-SUIIP Aft Tube
2. C-SIIIIP Forward Tube
3. Bolt
4. Nut
5. Bolt
6. Nut
7. CUshioned Cla.p
8. CUshioned Cla.p
9. Bolt
10. Stage 7 Air Tube
11. Gasket
12. Bolt
13. Nut
14. Bolt
15. Nut
16. Stage 7 Gasket
17. Gasket
18. A-SUIIIP Pressure Valve
Atr Metal Tube
19. Nut
Figure I.
20. Bolt
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Gasket
Drain Separator Tube
Nut
Bolt
CUshioned Cla.p
Bracket
CUshioned Cl up
Bracket
Nipple
Packing
Pressure Regulating
Valve Assellbly
Bracket
Bracket
Bracket
eo.bustton Chamber Fra.e
36.
37.
38.
39.
Compressor Stator Casing Assembly
Rear Main Mount
Grmaet
Ignition Lead
40. Stage 7 Balance Piston
Atr Tube
41. Balance Piston Duct Support
42. Orifice Plate
43. Bolt
44. Bolt
45. Washer
OOOLM5-05020A
Removal and Installation of Seal Pressurizing System Components
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
PageS
31 May 2002
5.
STAGE 7 AIR TUBE.
a.
Remove stage 7 air tube (I 0. figure I) as follows:
(I)
Remove bolt (5) and nut (6) that secure cushioned clamp (8) to clamp on feedback cable.
(2)
Remove bolt (5) and nut (6) that secure cushioned clamp (8 ). on tube (I 0), to cushioned clamp (7) on
C-sump forward tube (2).
(3)
Remove two bolts ( 12) and nuts ( 13) that connect tube (I 0) to pressure regulating valve assembly (31 ).
( 4)
Disconnect coupling nut on stage 7 balance piston air tube (40). from fitting on tube ( 10).
(5)
Remove four bolts ( 14) and nuts ( 15) that connect tube (I 0) to compressor stator casing assembly (36).
(6)
Remove and discard lockwire from four bolts (9). Remove bolts (9) that secure tube (10) to boss on combustion chamber frame (35).
b.
(7)
Remove tube (I 0).
(8)
Remove two clamps (8) from tube. Remove and discard gaskets ( 11. 16. 17).
Install stage 7 air tube (I 0) as follows:
(I)
Install and position two clamps (8) onto tube (I 0) at locations shown.
(2)
Install new gasket ( 11) onto boss of combustion chamber frame (35).
(3) Position tube (I 0). as shown. and secure flange of tube onto boss of combustion chamber frame (35) with
four bolts (9). Hand-tighten bolts.
(4) Install new gasket ( 16) onto flange of compressor stator casing assembly (36 ). Position f1ange of tube (I 0)
onto flange of casing assembly. and install four bolts ( 14) and nuts ( 15 ). Hand-tighten nuts.
(5)
Using bolt (5) and nut (6). secure cushioned clamp (8) to clamp on feedback cable. Torque nut to
38-42 lh in. (4.3-4.7 N·m).
(6) Using bolt (5) and nut (6 ). secure cushioned clamp (8) to cushioned clamp (7) on C-sump forward tube (2).
Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(7)
Torque four bolts (9) to 105-115 lb in. ( 11.9-13.0 N·m). Using 0.032 inch (0.81 mm) diameter lock wire.
lock-wire bolts using the double-strand method (WP 007 00).
(8)
Torque four nuts (15) to 38-42 lb in. (4.3-4.7 N·m).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page6
I CAUTION I
The mating flange of pressure regulating valve
assembly (31) that will connect with the mating flange of
tube (I 0) must not have an alignment pin hole. If the flange
has an alignment pin hole. the valve assembly is not
installed correctly and may fail during operation.
(9) Check the mating flange of valve assembly (31) to be sure that the flange does not have an alignment pin
hole. If the flange has an alignment pin hole. remove and test valve assembly (para 13 ).
(I 0) Install new gasket ( 17) onto mating flange of valve assembly (31 ). Install two bolts ( 12) (boltheads facing
down) and nuts ( 13) to secure tube (I 0) onto valve assembly. Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(11) Connect coupling nut on tube (40) to fitting on tube (I 0). Torque coupling nut to 900-1100 lb in.
(101.7-124.3 N·m).
6.
C-SUMP FORWARD TUBE.
a.
Remove C-sump forward tube (2. figure I ) as follows:
(I)
Remove bolt (3) and nut (4) that secure cushioned clamp (7) to bracket (34) on combustion-to-transition
(2)
tion lead (39).
Remove bolt (3) and nut (4) that secure cushioned clamp (7) on tube (2), to cushioned clamp (7) on igni-
flange.
(3)
Remove bolt (5) and nut (6) that secure cushioned clamp (7) on tube (2), to cushioned clamp (8) on stage 7
(4)
Using two wrenches. disconnect coupling nut on tube (2). from fitting on A-sump pressure valve air metal
(5)
Using two wrenches. disconnect coupling nut on C-sump aft tube (I). from fitting on tube (2).
(6)
Remove grommet (38) from rear main mount (37).
(7)
Slide tube (2) from rear main mount (37).
(8)
Remove three cushioned clamps (7) from tube (2).
air tube (I 0).
tube(l8).
b.
Install C-sump forward tube (2) as follows:
(I)
Install and position three cushioned clamps (7) onto tube (2) at locations shown.
(2)
Position tube (2) as shown. Slide one end of tube through hole in rear main mount (37 ).
(3)
Install grommet (38) into rear main mount (37).
(4)
Connect coupling nut on tube (2). to fitting on A-sump pressure valve air metal tube (18). Hand-tighten
coupling nut.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
Page7
31 May 2002
(5)
Connect coupling nut on C-sump aft tube (I). to fitting on tube (2). Hand-tighten coupling nut.
(6) Using bolt (5) and nut (6). secure cushioned clamp (7) to cushioned clamp (8) on stage 7 air tube (10).
Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(7)
Using bolt (3) and nut (4). secure cushioned clamp (7) on tube (2). to cushioned clamp (7) on ignition
lead (39). Torque nut to 38-42lb in. (4.3-4.7 N·m).
(8) Using bolt (3) and nut (4). secure cushioned clamp (7) to bracket (34) on combustion-to-transition flange.
Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(9)
Torque coupling nut on tube (2). to 270-300 lb in. (30.5-33.9 N·m).
( 10) Torque coupling nut on tube (I). to 270-300 lb in. (30.5-33.9 N·m).
7.
DRAIN SEPARATOR TUBE.
a.
Remove drain separator tube (22. figure I) as follows:
(I)
Remove two bolts (24) and nuts (23) that secure two cushioned clamps (27) to brackets (28) on accessory
(2)
Disconnect coupling nut on tube (22), from fitting on A-sump pressure valve air metal tube ( 18). Remove
(3)
Remove cushioned clamps (27) from tube.
gearbox.
tube (22).
b.
Install drain separator tube (22) as follows:
(I)
Install and position two cushioned clamps (27) onto tube (22) at locations shown.
(2)
Connect coupling nut on tube (22). to fitting on tube (18 ). Hand-tighten coupling nut.
(3) Using two bolts (24) and nuts (23). secure cushioned clamps (27) to brackets (28) on accessory gearbox.
Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(4)
8.
Torque coupling nut on tube (22), to 180-200 lb in. (20.3-22.6 N·m).
A-SUMP PRESSURE VALVE AIR METAL TUBE.
a.
Remove A-sump pressure valve air metal tube ( 18, figure I) as follows:
(I)
Remove bolt (24) and nut (23) that secure cushioned clamp (25) to bracket (32) on cover plate.
(2)
Remove bolt (24) and nut (23) that secure cushioned clamp (25) to bracket (26) on accessory gearbox.
(3)
Using two wrenches. disconnect coupling nut on C-sump forward tube (2), from fitting on tube (18).
(4)
Disconnect coupling nut on drain separator tube (22), from fitting on tube ( 18).
(5) Disconnect hose from tube (18). Using two wrenches. disconnect coupling nut on tube (18). from
nipple (29) on front frame.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
021 00
GEK 99441
Page 8
31 May 2002
b.
(6)
Remove two bolts (20) and nuts ( 19) that secure tube ( 18) to pressure regulating valve assembly (31 ).
(7)
Remove tube ( 18). Remove and discard gasket (21 ).
(8)
Remove two cushioned clamps (25) from tube ( 18 ).
(9)
Remove nipple (29) and packing (30) from front frame. Discard packing.
Install A-sump pressure valve air metal tube ( 18) as follows:
Lubricating Oil
66
( 1) Using a light coat of lubricating oil MIL-L-7808 or MIL-L-23699. lubricate packing (30) and packing
groove on nipple (29). Install packing onto nipple.
(2)
Install nipple (29) into boss on front frame. Torque nipple to 270-300 lb in. (30.5-33.9 N·m).
(3)
Install and position two clamps (25) onto tube ( 18) at locations shown.
(4)
Position tube (18 ). as shown, between nipple (29) and pressure regulating valve assembly (31 ).
(5)
Connect coupling nut on tube ( 18) to nipple (29). Hand-tighten coupling nut.
I CAUTION I
The mating flange of valve assembly (31) that will connect
with the mating flange of tube (18) must have an alignment
pin hole. If the flange does not have an alignment pin hole,
the valve assembly is not installed correctly and may fail
during operation.
(6) Check the mating flange of valve assembly (31) to be sure that the flange has an alignment pin hole. If the
flange does not have an alignment pin hole, remove and test valve assembly (para 13 ).
I CAUTION I
The alignment pin on mating flange of tube ( 18) must align
with the hole in gasket (21 ). and with the hole in mating
flange of valve assembly (31 ). Otherwise. leaks will occur.
(7)
Install new gasket (21) between mating flanges of valve assembly (31) and tube ( 18 ). Be sure that the
alignment pin on tube aligns with hole in gasket. and with alignment pin hole on flange of valve assembly (31 ).
(8) Using two bolts (20) (boltheads facing down) and nuts ( 19). secure flange of tube ( 18) to flange of valve
assembly (31 ). Hand-tighten nuts.
(9)
Connect coupling nut on drain separator tube (22) to fitting on tube ( 18). Hand-tighten coupling nut.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page9
(I 0) Connect coupling nut on C-sump forward tube (2) to fitting on tube (18). Hand-tighten coupling nut.
(11) Using bolt (24) and nut (23). secure cushioned clamp (25) to bracket (26) on accessory gearbox.
(12) Using bolt (24) and nut (23). secure cushioned clamp (25) to bracket (32) on cover plate. Torque bolt (24)
to 38-42 lb in. (4.3-4.7 N·m).
(13) Torque two nuts (19) to 38-42lb in. (4.3-4.7 N·m).
( 14) Using two wrenches. torque coupling nut on tube (18) to 450-550 lb in. (50.8-62.1 N·m).
(15) Using two wrenches. torque coupling nut on tube (2) to 270-300 lb in. (30.5-33.9 N·m).
(16) Using two wrenches, torque coupling nut on tube (22) to 180-200 lb in. (20.3-22.6 N·m).
( 17) Torque two nuts (23) to 38-42 lb in. (4.3-4.7 N·m).
(18) Connect hose to tube (18). Using two wrenches, torque coupling nut on hose to 270-300 lb in.
(30.5-33.9 N·m).
9.
STAGE 7 BALANCE PISTON AIR TUBE.
a.
Remove stage 7 balance piston air tube (40. figure I) as follows:
(I)
Remove and discard lock wire from two bolts (43 ). Remove bolts that secure tube (40) to duct on front
(2)
Disconnect coupling nut on tube (40) from fitting on stage 7 air tube (I 0). Remove tube (40).
(3)
Remove orifice plate (42) from tube (40).
frame.
(4) Remove and discard lockwire from bolt (44). Remove bolt (44). washer (45), and balance piston duct
support (41) from front frame.
b.
Install stage 7 balance piston air tube (40) as follows:
(I) Using washer (45) and bolt (44 ). secure support (41) onto front frame. Torque bolt to 38-42 lb in.
(4.3-4.7 N·m). Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire bolt using the double-strand method (WP 007 00).
(2)
Connect coupling nut on tube (40) to fitting on stage 7 air tube (I 0). Hand-tighten coupling nut.
(3)
Install orifice plate (42) between flange of tube (40) and duct on front frame.
(4)
Using two bolts (43 ), secure tube (40) to the flange on front frame and to the support (41 ).
(5) Torque bolts (43) to 105-115 lb in. (11.9-13.0 N·m). Using 0.032 inch (0.81 mm) diameter lockwire. lockwire bolts using the double-strand method (WP 007 00).
(6)
Torque coupling nut on tube (40) to 900-1100 lb in. (101.7-124.3 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
10.
Page 10
CLEANING OF TUBES.
a.
Flush tubes in clean water. and air-dry them.
32
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
b.
Using dry cleaning solvent P-D-680. flush the external and internal surfaces of tubes.
c.
Rinse the external and internal surfaces of tubes with filtered water.
I WARNING I
Compressed Air
•
•
•
•
d.
11.
When using compressed air for any cooling. cleaning,
or drying operation. do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench, wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench. wear approved respirator and goggles.
Using dry, filtered compressed air. dry the tubes.
INSPECTION OF TUBES.
Go to table I.
TABLE 1.
Inspect
a.
INSPECTION OF TUBES
Usable Limits
Max Repairable Limits
Corrective Action
Tubes for:
(I) Splits and cracks.
None allowed.
Not repairable.
Replace tube.
(2) Nicks. scratches.
gouges. and
chafing.
Any number, up to 0.008 inch
(0.20 mm) deep. without high
metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
(3) Dents.
Dented area must not exceed
20% of tube diameter.
Not repairable.
Replace tube.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 11
TABLE 1.
b.
c.
INSPECTION OF TUBES (Cant)
Inspect
Usable Limits
(4) Flattened area.
Outside diameter must not be
less than 3/4 of the original
diameter.
Not repairable.
Replace tube.
(5) Distortion.
Any amount. if tube can be
installed without force.
Any amount.
Cold-work (WP 007 00)
tube to make it fit properly,
without force. Cracks and
kinks are not allowed.
Pressure-test tube
(para 12).
(I) Cracks.
None allowed.
Not repairable.
Replace tube.
(2) Damaged
corners.
Any amount. if a wrench can
be used.
Not repairable.
Replace tube.
(3) Nicks and burrs.
Any number. without high
metal.
Any number. with high metal.
Using a fine abrasive stone
(WP 007 00), remove high
metal.
(4) Damaged threads.
One-half of one thread
(cumulative). without high
metal.
Same as usable limits. with
high metal.
Using a bottoming tap,
chase threads.
(I) Cracks.
None allowed.
Not repairable.
Replace tube.
(2) Circumferential
Any number that cannot be
felt with a scriber having a
0.030 inch (0.76 mm) tip
radius. without high metal.
Same as usable limits, with
high metal.
Using a fine abrasive
stone, remove high metal
(WP 007 00). Pressuretest tube (para 12 ).
None allowed.
Any number.
Using a fine abrasive stone
(WP 007 00), blend defect.
maintaining original contour. Pressure-test tube
(para 12).
One-half of one thread
(cumulative). without high
metal.
Same as usable limits, with
high metal.
Using a die. chase threads.
Max Repairable Limits
Corrective Action
Hex coupling nuts for:
Male fittings for:
nicks and
scratches, and
shiny. burnished
surfaces on the
seating surface.
(3) Axial nicks and
scratches, and
pits on the seating
surface.
(4) Damaged threads.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 12
TABLE 1.
Inspect
d.
Usable Limits
Max Repairable Limits
scratches, ridges,
and pits on
seating surface.
(2) Nicks and gouges
on tube flare.
Any number, if the defect
does not extend more than
half way across seating surface. without high metal.
Same as usable limits. with
high metal.
Using a fine abrasive stone
(WP 007 00). blend defect.
maintaining original contour. Pressure-test tube
(para 12).
Any number. 0.0 I 0 inch
(0.25 mm) deep, without high
metal. if tube passes the pressure test.
Same as usable limits. with
high metal.
Blend high metal
(WP 007 00). Pressuretest tube (para 12).
None allowed.
Not repairable.
Replace tube.
Tube flare ferrules
for:
(I) Cracks.
Penetrating Oil
f.
12.
Corrective Action
Femal fittings for:
(I ) Nicks, dents,
e.
INSPECTION OF TUBES (Cont)
234
(2) Adhesion to
coupling nuts.
Any amount, if nut turns
smoothly on ferrule.
Any amount. if the nut can be
worked free to turn smoothly
on ferrule.
Apply penetrating oil
VV-P-216 to the nut, and
work it free. Using a lintfree cloth, remove all
traces of penetrating oil.
Mating flanges for
flatness (hold flange
against a flat surface
and try to insert a
0.005 inch (0.13 mm)
shim).
Flange must be flat within
0.005 inch (0.13 mm).
Up to 25'7c of original flange
thickness can be reworked to
meet usable limits.
Rework flange to usable
limits by lapping, stoning.
or machining (if possible).
PRESSURE-TEST OF TUBES.
Calibrating Fluid, MIL-C-7024
a.
21
Using calibrating fluid MIL-C-7024, flush tube thoroughly.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
021 00
GEK 99441
31 May 2002
Page 13
I WARNING I
High-Pressure Testing
•
•
•
•
13.
High pressures used during testing may cause rupturing or bursting of faulty tubes and hoses. The result
could be serious injury.
To prevent injury. cover all tubes and hoses with a
suitable safety shield during testing.
When caps or plugs arc used. be sure they arc securely
installed to prevent them from being blown out.
Be sure that pressures are bled off before exposing or
touching hoses or tubes.
b.
Restrict one end of tube. Using calibrating fluid MIL-C-7024. build up pressure to 200 psig ( 1379 kPa).
c.
Maintain pressure for a minimum of 2 minutes. If there is a pressure drop. replace tube.
d.
Thoroughly drain tube of excess fluid. Cap or plug open ends.
PRESSURE REGULATING VALVE ASSEMBLY.
a.
Remove pressure regulating valve assembly (31, figure I) as follows:
(I)
(2)
metal tube ( 18 ).
(3)
b.
Using instructions in paragraph 5. disconnect stage 7 air tube (I 0).
Remove two bolts (20) and nuts ( 19) that secure the valve assembly 01) to A-sump pressure valve air
Remove valve assembly (31 ). Remove and discard gaskets ( 17, 21 ).
Test the valve assembly (see figure 2) as follows:
(I)
Using kit adapter 21 C5536. set up valve assembly for testing as shown in figure 2.
(2) Using the control valve, vary the inlet air pressure from 20 to 80 psig ( 138 to 552 kPa). The discharge
(regulated) air pressure must be maintained at 12.5-17.5 psig (86-121 kPa), without resonance or instability. Record the minimum and maximum discharge (regulated) air pressure.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 14
DISOfARGE AIR
REQUIREMENTS
• AIR SUPPLY: SHOP AIR REGULATED BETHEEN
20 AND 80 PSIG (138-552 kPa) FOR AIR
FLOH FROM 0.003 TO 0.007 LB/SEC.
(1.36-3.17 GRAMS/SEC.).
PRESSURE REGULATING
VALVE ASSEMBLY
• DISOfARGE SIDE: FITTED HITH AN ORIFICE RESTRICTION
(SEE VIEH A FOR DETAILS).
VOLUME BETWEEN VALVE OUTLET AND ORIFICE
RESTRICTION MUST BE 20-40 CUBIC INCHES
(328-656 CUBIC CENTIMETERS).
• GAGES: ACOJRATE WITHIN 1'L OF AJLL SCALE READING.
SECTION VIEW
CONTROL VALVE
OUTLET AIR GAGE
0-30 PSIG
(0-207 kPa>
INLET AIR GAGE
0-100 PSIG
(0-689 kPa)
INLET
(SHOP AIR AT
AMBIENT
TEMPERATURE)
AIR
FILTER
(10
PRESSURE
REGULATING
VALVE
A
BY
DISCHARGE AIR
12.5-17.5 PSIG
.___,_-t ORIFICE 1---(-86-....,.12-1 kPa)
CVIEH A)
MICRON)
TEST SETUP
1
(0.81)
0.020 <0.51 >
- - - - ______
,r-0.113 (2.870)
0.111 (2.819)
DIA
0.75 (19.1)
DIA MINIHI.IH
VIEW A
ALL DIMENSIONS ARE IN INCHES WITH
MIWMETERS IN PARENTHESES.
Figure 2.
1201106-00-A2A
Testing of Pressure Regulating Valve Assembly
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
021 00
GEK 99441
31 May 2002
(3)
Page 15
If the discharge (regulated) air pressure is not maintained throughout the range of supply air pressure. do
the following:
(a)
Disassemble valve assembly (see figure 3) as follows:
I WARNING I
Handling Spring-Loaded Parts
To avoid injury. use care when removing valve cap (3),
because spring (5) is under compression.
I CAUTION I
The nuts (I) should be alternately loosened one turn at a
time. to avoid deformation of valve cap (3) as spring pressure is relieved.
I
Alternately loosen two nuts (I) from valve cap (3 ), until spring pressure is relieved.
2
Remove two nuts (I) and bolts (2) from valve cap (3).
7
1
1.
2.
3.
4.
5.
Nut
Bolt
Valve Cap
Shim
Spring
--------
--------
----
... __
6. Retainer Assembly
7. Valve Cover
8. Valve Piston
9. Valve Body
1201107-00-02
Figure 3.
Disassembly. Inspection. and Assembly of Pressure Regulating Valve Assembly
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 16
NOTE
There may be more than one shim (4) between valve cap (3)
and spring (5).
(b)
3
Remove valve cap (3) and shim (4). Save shim for installation.
4
Remove spring (5) and retainer assembly (6).
5
Remove two nuts (I). bolts (2). and valve cover (7).
6
Remove valve piston (8) from valve body (9).
Clean the components of valve assembly as follows:
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
I
32
Flush the components of valve assembly with dry cleaning solvent P-D-680.
2 Using a soft-bristle brush soaked with dry cleaning solvent P-D-680, remove any debris that has
accumulated onto components.
3
Flush the components of valve assembly with dry cleaning solvent P-D-680.
I WARNING I
Compressed Air
•
•
•
•
4
(c)
When using compressed air for any cooling. cleaning,
or drying operation. do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench. wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench. wear approved respirator and goggles.
Using dry. filtered. low-velocity compressed air, dry the components of valve assembly.
Inspect components of valve assembly as instructed in table 2.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
TABLE 2.
Page 17
INSPECTION OF PRESSURE REGULATING VALVE ASSEMBLY COMPONENTS
Inspect
a.
Usable Limits
Max Repairable Limits
Corrective Action
Valve body (9,
figure 3) for:
(I) Cracks.
None allowed.
Not repairable.
Replace valve body.
(2) Wear in bore A.
1.002 inches (25.45 mm)
maximum average diameter
(measured at three locations).
Not repairable.
Replace valve body.
(3) Wear in bore B.
0.502 in. ( 12.75 mm) maximum average diameter (measured at three locations).
Not repairable.
Replace valve body.
(a) Bores A
and B.
None allowed.
Not repairable.
Replace valve body.
(b) Other areas.
Any number, 0.016 inch
(0.41 mm) deep, without high
metal.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00).
(I) Cracks.
None allowed.
Not repairable.
Replace valve piston.
(2) Wear on
0.4955 inch ( 12.586 mm)
minimum average diameter
(measured at three locations).
Not repairable.
Replace valve piston.
0.9955 inch (25.286 mm)
minimum average diameter
(measured at three locations).
Not repairable.
Replace valve piston.
(a) Diameters C
and D.
None allowed.
Not repairable.
Replace valve piston.
(b) Other areas.
Any number. 0.016 inch
(0.41 mm) deep, without high
metal.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00).
(I) Cracks.
None allowed.
Not repairable.
Replace spring.
(2) Rub marks on
Rub marks allowed up to
0.020 inch (0.51 mm) wide.
Not repairable.
Replace spring.
(4) Nicks, dents. and
scratches in:
b.
Valve piston (8) for:
diameter C.
(3) Wear on
diameter D.
(4) Nicks. dents. and
scratches on:
c.
Spring (5) for:
coils.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
Page 18
31 May 2002
TABLE 2.
INSPECTION OF PRESSURE REGULATING VALVE ASSEMBLY COMPONENTS (Cont)
Inspect
Usable Limits
(3) Relaxation and
Corrective Action
Length of spring must be
1.20-1.25 inches
(30.5-31.8 mm) in free state.
Not repairable.
Replace spring.
Any number. 0.016 inch
(0.41 mm) deep, without high
metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
(I) Cracks.
None allowed.
Not repairable.
Replace part.
(2) Nicks, dents. and
scratches.
Any number. 0.016 inch
(0.41 mm) deep. without high
metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
permanent set.
(4) Nicks. dents. and
scratches.
d.
Max Repairable Limits
Valve cap (3). retainer
assembly (6). and
valve cover (7) for:
(d)
Assemble valve assembly (see figure 3) as follows:
I
Install valve cover (7) onto valve body (9). Using two bolts (2) and nuts (I), secure valve cover.
Torque nuts to 25-30 lb in. (2.8-3.4 N·m).
2
Install valve piston (8) into valve body (9) until piston bottoms.
3
Insert the retainer assembly (6) into the recess of valve piston (8). so that the ball end faces the
4
Install spring (5) onto retainer assembly (6).
valve piston.
NOTE
•
•
The regulated pressure from the valve assembly is
determined by the spring preload. The shim
PN 20 18T 15PO I ( 4) is used to set the preload.
Adding one shim (4) increases the output pressure
approximately 0.75 psi (5.2 kPa).
5
Using the test results recorded in step b.(2). change the number of shims (4) as required to adjust
the discharge air pressure within limits. If more than six shims are required to achieve correct discharge air pressure regulation, replace valve assembly. Return the replaced valve assembly to the vendor for repair.
6
Install the required shims (4) into the inner recess of valve cap (3 ).
7
Install valve cap (3) onto valve body (9). Using two bolts (2) and nuts (I). secure valve cap.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
021 00
31 May 2002
Page 19/20
CAUTION
The nuts (I) should be alternately tightened one turn at a
time, to avoid deformation of valve cap (3) as spring pressure mcreases.
8
Alternately tighten nuts (I) on valve cap (3 ).
9
Torque nuts (I) to 25-30 lb in. (2.8-3.4 N·m).
I 0 Re-test valve assembly.
c.
Install pressure regulating valve assembly (31, figure I) as follows:
I CAUTION I
The mating flange of valve assembly (31) that will connect
with the mating flange of A-sump pressure valve air metal
tube ( 18) must have an alignment pin hole. If the flange
does not have an alignment pin hole. the valve assembly
will not be installed correctly and may fail during operation.
(I)
Position the valve assembly (31) so that the mating flange with the alignment pin hole faces the mating
flange of tube (18).
CAUTION
The alignment pin on mating flange of tube ( 18 ), must align
with the hole in gasket (21 ), and with the hole in mating
flange of valve assembly (31 ). Otherwise. leaks will occur.
(2) Install new gasket (21) between flanges of valve assembly (31) and tube (18). Be sure that the alignment
pin on tube aligns with hole in gasket and with alignment pin hole on flange of valve assembly.
(3) Using two bolts (20) (boltheads facing down) and nuts (19). secure flange of tube (18) to Jlange of valve
assembly (31). Torque nuts to 38-42lb in. (4.3-4.7 N·m).
(4)
Using instructions in paragraph 5. re-connect stage 7 air tube (I 0) to valve assembly (31 ).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 1 of 36
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
SEAL PRESSURIZING AND B-SUMP REGULATING SYSTEM COMPONENTS
REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
(LEVEL 2 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
MARINE GAS TURBINE
Alphabetical Index
Subject
Air Regulator Valve Tube (G03/-G04/-G05/-G06 only) ......................................
Cleaning ........................................................................
Inspection ......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
A-Sump Pressure Valve Air Metal Tube ..... ·.............................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
B-Sump Oil Tube (G03/-G04/-G05/-G06 only) ............................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
B-Sump Regulator Valve (G03/-G04/-G05/-G06 only) ......................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Consumable Materials ................................................................
C-Sump Aft Tube ...................................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
Page No.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
24
26
26
24
28
24
16
26
26
17
28
16
24
26
26
24
28
24
35
36
36
35
4
5
26
26
5
28
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
5
GEK 99441
02110
31 May 2002
Page2
Alphabetical Index (Cant)
Subject
C-Sump Forward Tube ............................................................... .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Drain Separator Tube (GOI/-G03/-G04 only) .............................................. .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Introduction ........................................................................ .
Pressure Regulating Valve Assembly (All Models) ......................................... .
Installation ...................................................................... .
Removal ........................................................................ .
Test ............................................................................ .
Regulator Valve Aft Air Tube (G03/-G04/-G05 only) ....................................... .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Regulator Valve Forward Air Tube (G03/-G04/-G05 only) ................................... .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Stage 7 Air Tube .................................................................... .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Stage 7 Balance Piston Air Tube ........................................................ .
Cleaning ........................................................................ .
Inspection ....................................................................... .
Installation ...................................................................... .
Pressure-Test. .................................................................... .
Removal ........................................................................ .
Page No.
14
26
26
14
28
14
15
26
26
16
28
15
4
29
35
29
29
22
26
26
22
28
22
22
26
26
23
28
22
5
26
26
11
28
5
20
26
26
21
28
20
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
02110
GEK 99441
Page3
31 May 2002
Alphabetical Index (Cant)
Page No.
Subject
Stage 7 Regulator Air Tube (G03/-G04/-G05/-G06 only) ....................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
Stage 7 Valve Air Tube (G05/-G06 only) .................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Pressure-Test. ....................................................................
Removal ........................................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
23
26
26
23
28
23
25
26
26
25
28
25
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
4
GEK 994.41
02110
31 May 2002
Page4
1. INTRODUCTION. This work package provides instructions for removing. cleaning. inspecting. and installing the seal
pressurizing and B-sump regulating system components.
2.
SUPPORT EQUIPMENT.
Support Equipment
3.
Part No.
Nomenclature
21C5536
Kit Adapter (for testing the pressure
regulating valve assembly)
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Brush. Soft-Bristle
Local Purchase
Caps, Protective
Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Cloth, Lint-Free
Local Purchase
Filter, !O-Micron
Local Purchase
Fluid. Calibrating (MIL-C-7024)
Local Purchase
Lockwire, 0.032 inch (0.81 mm) diameter
Local Purchase
OiL Lubricating
(MIL-L-7808 or MIL-L-23699)
Local Purchase
Oil, Penetrating (VV-P-216)
Local Purchase
Plugs. Protective
Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Solvent, Dry Cleaning (P-D-680)
Local Purchase
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
PageS
31 May 2002
4.
C-SUMP AFT TUBE.
a.
Remove C-sump aft tube (I. figure I. sheet I) as follows:
(I)
Remove bolt (3) and nut (4) that secure cushioned clamp (7) to bracket (32) on exhaust frame.
(2)
Remove bolt (3) that secures cushioned clamp (7) to bracket (33) on low-pressure turbine (Lff) casing.
(3)
forward tube (2).
(4)
b.
Using two wrenches. disconnect coupling nuts on tube (I) from fitting on exhaust frame and from C-sump
Remove tube (I ). Remove two cushioned clamps (7) from tube.
Install C-sump aft tube (I) as follows:
(I)
Install and position two cushioned clamps (7) onto tube (I) at locations shown.
(2) Connect coupling nuts on tube (I), to fitting at the 12 o'clock position on exhaust frame and to C-sump forward tube (2). Hand-tighten coupling nuts.
(3) Using bolt (3) and nut (4). secure cushioned clamp (7) to bracket (32) on exhaust frame. Torque nut to
38-42 lb in. (4.3-4.7 N·m).
(4)
(4.3-4.7 N·m).
(5)
5.
Using bolt (3). secure cushioned clamp (7) to bracket (33) on Lff casing. Torque bolt to 38-42 lb in.
Torque coupling nuts on tube (I) to 270-300 lb in. (30.5-33.9 N·m).
STAGE 7 AIR TUBE.
a.
Removal.
(I)
On L32119GO I configuration. remove stage 7 air tube (I 0. figure I. sheet I) as follows:
(a)
Remove bolt (5) and nut (6) that secure cushioned clamp (8) to clamp on feedback cable (70).
(b) Remove bolt (5) and nut (6) that secure cushioned clamp (8). on tube (I 0), to cushioned clamp (7) on
C-sump forward tube (2).
(c)
Remove two bolts (12) and nuts (13) that connect tube (I 0) to pressure regulating valve
(d)
Disconnect coupling nut on stage 7 balance piston air tube (40) from fitting on tube (I 0).
(e)
Remove four bolts ( 14) and nuts ( 15) that connect tube (I 0) to compressor stator casing
(f)
Remove and discard lockwire from four bolts (9).
(g)
Remove four bolts (9) that secure tube ( 10) to boss on combustion chamber frame (35).
(h)
Remove tube (10) from GT.
assembly (31 ).
assembly (36 ).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
Page6
31 May 2002
1201205-00-A2A
Figure 1.
.. e an d B-Sum P R egulatin<>
Removal and I nstallation of S,eal Press
c system Corn ponents (Sheet I of 4)
· · unzmcr
GE PROPRIETARY INFORM ATION -
s ub]ect
. to the restnctlons
. .
on th e cover or first page.
02110
GEK 99441
Page7
31 May 2002
LEGEND:
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.
33.
34.
35.
36.
37.
38.
39.
40.
41.
C-SUMP AFT TUBE
C-SUMP FORWARD TUBE
BOLTS
NUTS
BOLT
NUT
CUSHIONED CLAMPS
CUSHIONED CLAMP
BOLT
STAGE 7 AIR TUBE
GASKET
BOLT
NUT
BOLT
NUT
GASKET
GASKET
A-SUMP PRESSURE VALVE AIR METAL TUBE
NUT
BOLT
GASKET
DRAIN SEPARATOR TUBE
NUT
BOLTS
CUSHIONED CLAMP
BRACKET
CUSHIONED CLAMP
BRACKET
NIPPLE
PREFORMED PACKING
PRESSURE REGULATING VALVE ASSEMBLY
BRACKET
BRACKET
BRACKET
COMBUSTION CHAMBER FRAME
COMPRESSOR STATOR CASING ASSEMBLY
REAR MAIN MOUNT RING
GROMMET
IGNITION LEAD
STAGE 7 BALANCE PISTON AIR TUBE
BALANCE PISTON SUPPORT
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
ORFICE PLATE
BOLT
BOLT
WASHER
BOLTS
REGULATOR VALVE AFT AIR TUBE
CUSHIONED CLAMP
NUT
REGULATOR VALVE FORWARD AIR TUBE
CUSHIONED CLAMP
CUSHIONED CLAMPS
CUSHIONED CLAMP
B-SUMP VENT TEE
AIR REGULATOR VALVE TUBE
B-SUMP REGULATOR VALVE
CUSHIONED CLAMP
B-SUMP OIL TUBE
STAGE 7 REGULATOR AIR TUBE
BOLT
NUT
CUSHIONED CLAMP
CUSHIONED CLAMP
STAGE 7 VALVE AIR TUBE
HOSE
BOLT
NUT
CUSHIONED CLAMP
CUSHIONED CLAMP
FEEDBACK CABLE
BRACKET
BOLT
CUSHIONED CLAMP
BRACKET
GROMMET
BOLT
NUT
GASKET
BOLT
NUT
CUSHIONED CLAMP
CUSHIONED CLAMP
1203644-00-A2A
Figure I.
Removal and Installation of Seal Pressurizing and B-Sump Regulating System Components (Sheet 2 of 4)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
Page 8
31 May 2002
L32119G05 AND G06
Figure I.
12011 08-18 mm
Action
none
none
none
monitor
repair on-site
repair off-site
dispose
Blade Side # 4
Crack Length
0-3 mm
4-5 mm
6-10 mm
11-13 mm
14-16 mm
16-18 mm
>18 mm
Action
none
none
none
monitor
repair on-site
repair off-site
dispose
GEK 99441
02110
31 May 2002
Page 14
(o)
Torque four nuts (15) to 38-42 lb in. (4.3-4.7 N·m).
(p) Connect coupling nut on stage 7 balance piston air tube (40) to fitting on tube (I 0). Torque coupling
nut to 900-1100 lb in. (101.7-124.3 N·m).
(q) Connect coupling nut on stage 7 regulator air tube (59, sheet 3) to fitting on tube (I 0). Torque coupling nut to 135-155lb in. (15.3-17.5 N·m).
6.
C-SUMP FORWARD TIJBE.
a.
Remove C-sump forward tube (2, figure I, sheet I ) as follows:
(I) On L32119GO I. G03. and G04 configurations, remove bolt (3) and nut (4) that secure cushioned clamp (7)
to bracket (34) on combustion-to-transition flange.
(2) On L32119GO I, G03, and G04 configurations, remove bolt (3) and nut (4) that secure cushioned clamp (7)
on tube (2). to cushioned clamp (7) on ignition lead (39).
(3) On L32119GO I, G03. and G04 configurations. remove bolt (5) and nut (6) that secure cushioned clamp (7)
on tube (2 ). to cushioned clamp (8) on stage 7 air tube ( 10).
(4) On L32119G03. G04. and G05 configurations. remove bolt (46. sheet 3) and nut (49) that secure cushioned
clamp (51) on tube (2). to cushioned clamp (51) on regulator valve forward air tube (50).
(5) On L32119G05 and G06 configurations. remove bolt (3. sheet 4) and nut (4) that secure cushioned
clamp (7) to bracket (34) on combustion to transistor flange.
(6)
metal tube (18 ).
Using two wrenches, disconnect coupling nut on tube (2, sheet I) from fitting on A-sump pressure valve air
(7)
Using two wrenches. disconnect coupling nut on C-sump aft tube (I) from fitting on tube (2).
(8)
Remove grommet (38) from rear main mount (37).
(9)
Slide tube (2) from rear main mount (37).
(I 0)
On L32119GO I, G03, and G04 configurations. remove three cushioned clamps (7, sheet I) from tube (2).
( 11) On L32119G05 and G06 configurations, remove one cushioned clamp (7) from tube (2).
(12) On L32119G03, G04, and G05 configurations. remove one cushioned clamp (51, sheet 3) from tube (2).
b.
Install C-sump forward tube (2, sheet I) as follows:
(I)
On L32119G03, G04. and G05 configurations. install one cushioned clamp (51, sheet 3) onto tube (2) as
(2)
On L32119G05 and G06 configurations, install one cushioned clamp (7. sheet I) onto tube (2) as shown.
(3)
On L32119GOI, G03, and G04 configurations. install three cushioned clamps (7) onto tube (2) as shown.
(4)
Position tube (2. sheet I) as shown. Slide one end of tube through hole in rear main mount (37).
shown.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 15
(5)
Install grommet (38) into rear main mount (37).
(6)
Connect coupling nut on tube (2). to fitting on A-sump pressure valve air metal tube ( 18 ). Hand-tighten
(7)
Connect coupling nut on C-sump aft tube (I). to fitting on tube (2). Hand-tighten coupling nut.
coupling nut.
(8) On L32119GOI, Gm. and G04 configurations. install bolt (5) and nut (6) to secure cushioned clamp (7) to
cushioned clamp (8) on stage 7 air tube (10). Torque nut to 38-42lb in. (4.3-4.7 N·m).
(9) On U2119GOI. Gm, and G04 configurations. install bolt (3) and nut (4) to secure cushioned
clamp (7) on tube (2), to cushioned clamp (7) on ignition lead (39). Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(I 0) On U2119GO I, Gm, and G04 configurations. install bolt (3) and nut (4) to secure cushioned clamp (7) to
bracket (34) on combustion-to-transition flange. Torque nut to 38-42 lb in. (4.3-4.7 N·m).
( 11) On L32119Gm, G04. and G05 configurations. install bolt (46, sheet 3) and nut (49) to secure cushioned
clamp (51). on tube (2). to cushioned clamp (51) on regulator valve forward air tube (50). Torque nut to 38-42 lb in.
(4.3-4.7 N·m).
( 12) On L32119G05 and G06 configuration. install bolt (3. sheet 4) and nut (4) to secure cushioned clamp (7) to
bracket (34) on combustion-to-transition flange. Torque nut (4) to 38-42lb in. (4.3-4.7 N·m).
(13) Torque coupling nut on tube (2. sheet I) to 270-300 lb in. (30.5-33.9 N·m).
(14) Torque coupling nut on tube (I) to 270-300 lb in. (30.5-33.9 N·m).
7.
DRAIN SEPARATOR TIJBE (G011-G03/-G04 only).
a.
Remove drain separator tube (22, figure I, sheet I) as follows:
(I)
Remove two bolts (24) and nuts (23) that secure two cushioned clamps (27) to brackets (28) on accessory
(2)
Disconnect coupling nut on tube (22). from fitting on A-sump pressure valve air metal tube ( 18). Remove
(3)
Remove cushioned clamps (27) from tube.
gearbox.
tube (22).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
Page 16
31 May 2002
b.
Install drain separator tube (22) as follows:
(I)
Install and position two cushioned clamps (27) onto tube (22) at locations shown.
(2)
Connect coupling nut on tube (22). to fitting on tuhe (18). Hand-tighten coupling nut.
(3) Using two bolts (24) and nuts (23 ). secure cushioned clamps (27) to brackets (28) on accessory gearbox.
Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(4)
8.
Torque coupling nut on tu he (22). to 180-200 lh in. (20.3-22.6 N·m).
A-SUMP PRESSURE VALVE AIR METAL TUBE.
a.
Removal.
(I) On L32119GO I, G03. and G04 configurations. remove A-sump pressure valve air metal tu he ( 18.
figure I. sheet I) as follows:
(a) On L32119GO I configuration. remove bolt (24) and nut (23) that secure cushioned clamp (25) to
bracket (32) on cover plate.
(h)
Remove bolt (24) and nut (23) that secure cushioned clamp (25) to bracket (26) on accessory
gearbox.
(c)
B-sump oil tube (58).
Remove holt (46. sheet 3) and nut (49) that secure cushioned clamp (52) to cushioned clamp (57) on
(d)
Using two wrenches. disconnect coupling nut on C-sump forward tube (2. sheet I). from fitting on
(e)
Disconnect coupling nut on drain separator tu he (22). from fitting on tube ( 18).
(f)
Disconnect hose (65) from tu he ( 18).
(g)
Using two wrenches. disconnect coupling nut on tube (18). from nipple (29) on front frame.
(h)
Remove two bolts (20) and nuts (19) that secure tube (18) to pressure regulating valve
(i)
Remove tu he ( 18). Remove and discard gasket (21 ).
(j)
Remove two cushioned clamps (25. sheet I) and cushioned clamp (52, sheet 2) from tube (18).
(k)
Remove nipple (29. sheet I) and preformed packing (30) from front frame. Discard packing.
tuhe ( 18).
assembly (31 ).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 17
(2) On L32119G05 and G06 configurations, remove A-sump pressure valve air metal tube ( 18,
figure I, sheet 4) as follows:
(a)
Remove bolt (24. sheet I) and nut (23) that secure cushioned clamp (25) to bracket (32) on cover
(b)
Remove bolt (24, sheet4) and nut (23) that secure cushioned clamp (25) to bracket (26) on accessory
(c)
Remove bolt (72) that secures cushioned clamp (73) on tube ( 18) to bracket (71 ).
(d)
Using two wrenches. disconnect coupling nut on C-sump forward tube (2. sheet I), from fitting on
(e)
Using two wrenches, disconnect coupling nut on tube (18), from nipple (29) on front frame.
(f)
Remove two bolts (20) and nuts ( 19) that secure tube ( 18) to pressure regulating valve
(g)
Remove tube ( 18). Remove and discard gasket (21 ).
(h)
Remove two cushioned clamps (25, sheet I) from tube ( 18).
(i)
Remove nipple (29, sheet I) and packing (30) from front frame. Discard packing.
plate.
gearbox.
tube (18).
assembly (31 ).
b.
Installation.
(I)
On L32119GO I, G03. and G04 configurations, install A-sump pressure valve air metal tube ( 18) as
follows:
Lubricating Oil
66
(a) Using a light coat of lubricating oil MIL-L-7808 or MIL-L-23699. lubricate preformed packing (30)
and packing groove on nipple (29). Install packing onto nipple.
(b)
Install nipple (29) into boss on front frame. Torque nipple to 270-300 lb in. (30.5-33.9 N·m).
(c) Install and position two cushioned clamps (25. sheet I) and cushioned clamp (52, sheet 3) onto
tube (18) at locations shown.
(d)
Position tube ( 18, sheet 1). as shown, between nipple (29) and pressure regulating valve
(e)
Connect coupling nut on tube ( 18). to nipple (29). Hand-tighten coupling nut.
assembly (31 ).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 994.41
02110
Page 18
31 May 2002
CAUTION
The mating flange of valve assembly (31) that will connect
with the mating tlange of tube ( 18) must have an alignment
pin hole. If the flange does not have an alignment pin hole,
the valve assembly is not installed correctly and may fail
during operation.
(f)
Check the mating tlange of valve assembly (31) to be sure that the tlange has an alignment pin hole.
If the flange does not have an alignment pin hole, remove and test valve assembly (para 19).
I CAUTION I
The alignment pin on mating flange of tube (18) must align
with the hole in gasket (21 ). and with the hole in mating
tlange of valve assembly (31 ). Otherwise. leaks will occur.
(g) Install new gasket (21) between mating flanges of valve assembly (31) and tube ( 18). Be sure that
the alignment pin on tube aligns with hole in gasket. and with alignment pin hole on flange of valve assembly (31 ).
(h) Using two bolts (20) (boltheads facing down) and nuts (19). secure flange of tube (18) to flange of
valve assembly (31 ). Hand-tighten nuts.
(i)
Connect coupling nut on drain separator tube (22) to fitting on tube ( 18 ). Hand-tighten coupling nut.
(j)
Connect coupling nut on C-sump forward tube (2) to fitting on tube ( 18). Hand-tighten coupling nut.
(k)
Using bolt (24) and nut (23). secure cushioned clamp (25) to bracket (26) on accessory gearbox.
(I)
On L32119GO I configuration. install bolt (24) and nut (23) to secure cushioned clamp (25) to
bracket (32) on cover plate. Torque bolt (24) to 38-42 lb in. (4.3-4.7 N·m).
(m)
Torque two nuts (19) to 38-42lb in. (4.3-4.7 N·m).
(n)
Using two wrenches, torque coupling nut on tube (18) to 450-550 lb in. (50.8-62.1 N·m).
(o)
Using two wrenches. torque coupling nut on tube (2) to 270-300 lb in. (30.5-33.9 N·m).
(p)
Using two wrenches. torque coupling nut on tube (22) to 180-200 lb in. (20.3-22.6 N·m).
(q)
Torque two nuts (23) to 38-42lb in. (4.3-4.7 N·m).
(r)
Connect hose (65) to tube (18). Using two wrenches. torque coupling nut on hose to 270-300 lb in.
(30.5-33.9 N·m).
(s)
Using bolt (46. sheet 2) and nut (49), secure cushioned clamp (52) to cushioned clamp (57). Torque
nut to 38-42 lb in. (4.3-4.7 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
02110
GEK 99441
Page 19
31 May 2002
(2)
On L32119G05 and G06 configurations, install A-sump pressure valve air metal tube (18) as follows:
Lubricating Oil
66
(a) Using a light coat of lubricating oil MIL-L-7808 or MIL-L-23699, lubricate preformed packing (30)
and packing groove on nipple (29). Install packing onto nipple.
(b)
Install nipple (29) into boss on front frame. Torque nipple to 270-300 lb in. (30.5-33.9 N·m).
(c) Install and position two cushioned clamps (25. sheet I) and cushioned clamp (52, sheet 2) onto
tube ( 18) at locations shown.
(d)
Install cushioned clamp (73, sheet 4) onto tube ( 18) as shown.
(e)
Position tube (18. sheet I), as shown. between nipple (29) and pressure regulating valve
(f)
Connect coupling nut on tube ( 18), to nipple (29). Hand-tighten coupling nut.
assembly (31 ).
I CAUTION I
The mating flange of valve assembly (31) that will connect
with the mating flange of tube ( 18) must have an alignment
pin hole. If the flange does not have an alignment pin hole.
the valve assembly is not installed correctly and may fail
during operation.
(g) Check the mating flange of valve assembly (31) to be sure that the flange has an alignment pin hole.
If the flange does not have an alignment pin hole. remove and test valve assembly (para 19).
I CAUTION I
The alignment pin on mating flange of tube (18) must align
with the hole in gasket (21 ). and with the hole in mating
flange of valve assembly (31 ). Otherwise. leaks will occur.
(h) Install new gasket (21) between mating flanges of valve assembly (31) and tube ( 18). Be sure that
the alignment pin on tube aligns with hole in gasket. and with alignment pin hole on flange of valve assembly (31 ).
(i)
Using two bolts (20) (boltheads facing down) and nuts (19), secure flange of tube ( 18) to flange of
valve assembly (31 ). Hand-tighten nuts.
(j)
Connect coupling nut on C-sump forward tube (2) to fitting on tube ( 18). Hand-tighten coupling nut.
(k)
Using bolt (24) and nut (23). secure cushioned clamp (25) to bracket (26) on accessory gearbox.
Using bolt (24) and nut (23) to secure cushioned clamp (25) to bracket (32) on cover plate. Torque
bolt (24) to 38-42 lb in. (4.3-4.7 N·m).
(I)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 20
(m) Install bolt (72) to secure cushioned clamp (73) on tube ( 18) to bracket (71 ). Torque bolt to
38-42 lb in. (4.3-4.7 N·m).
9.
(n)
Torque two nuts (19) to 38-421b in. (4.3-4.7 N·m).
(o)
Using two wrenches, torque coupling nut on tube ( 18) to 450-550 lb in. (50.8-62.1 N·m).
(p)
Using two wrenches, torque coupling nut on tube (2) to 270-300 lh in. (30.5-33.9 N·m).
(q)
Torque nut (23) installed in step (k) to 38-421h in. (4.3-4.7 N·m).
STAGE 7 BALANCE PISTON AIR TUBE.
a.
Removal
(I)
On L32119GO I. G03. and G04 configurations, remove stage 7 balance piston air tube (40.
figure I. sheet 1) as follows:
(a)
Remove and discard lockwire from two bolts (43).
(h)
Remove two bolts (43) that secure tube (40) to duct on front frame.
(c) Remove three nuts (49, sheet 3) and bolts (46) that secure cushioned clamps (52) to cushioned
clamps (53) on air regulator valve tube (55). Remove cushioned clamps from tube.
(d)
Disconnect coupling nut on tube (40, sheet I) from fitting on stage 7 air tube (10). Remove
(e)
Remove orifice plate (42) from tube (40).
(f)
Remove and discard lockwire from bolt (44).
(g)
Remove bolt (44 ). washer (45). and balance piston duct support (41) from front frame.
tube (40).
(2)
On L32119G05 and G06 configurations, remove stage 7 balance piston air tube (40. figure I. sheet 4) as
follows:
(a)
Remove and discard lockwire from two bolts (43).
(h)
Remove two bolts (43) that secure tube (40) to duct on front frame.
(c) Remove two nuts (49, sheet 3. View A) and bolts (46) that secure cushioned clamps (52) to cushioned clamps (53) on air regulator valve tube (55). Remove cushioned clamps from tube.
(d)
Disconnect coupling nut on tube (40. sheet I) from fitting on stage 7 air tube (I 0). Remove
(e)
Remove orifice plate (42) from tube (40).
(f)
Remove and discard lock wire from bolt (44 ).
(g)
Remove bolt (44 ). washer (45 ). and balance piston duct support (41 ) from front frame.
tube (40).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
b.
Page 21
Installation
(I)
On L32119GO I. G03. and G04 configurations, install stage 7 balance piston air tube (40, sheet I) as
follows:
(a)
Using washer (45) and bolt (44 ), secure support (41) onto front frame. Torque bolt to 38-42 lb in.
(b)
Using 0.032 inch (0.81 mm) diameter lock wire. lock-wire bolt (44) using the double-strand method
(c)
Connect coupling nut on tube (40) to fitting on stage 7 air tube (10). Hand-tighten coupling nut.
(d)
Install orifice plate (42) between Jlange of tube (40) and duct on front frame.
(e)
Using two bolts (43). secure tube (40) to the flange on front frame and to the support (41 ).
(f)
Torque bolts (43) to 105-115lb in. (11.9-13.0 N·m).
(g)
Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire bolts
(h)
Torque coupling nut on tube (40) to 900-1100 lb in. (101.7-124.3 N·m).
(i)
Install and position three cushioned clamps (52, sheet 3) onto tube (40) at locations shown.
(4.3-4.7 N·m).
(WP 007 00).
the double-strand method
(WP 007 00).
(j)
Using three bolts (46) and nuts (49), secure cushioned clamps (52) to cushioned clamps (53) on air
regulator valve tube (55). Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(2)
On L32119G05 and G06 configurations, install stage 7 balance piston air tube (40. sheet I) as follows:
(a)
Using washer (45) and bolt (44 ), secure support (41) onto front frame. Torque bolt to 38-42 lb in.
(b)
Using 0.032 inch (0.81 mm) diameter lockwire. lock-wire bolt (44) using the double-strand method
(c)
Connect coupling nut on tube (40, sheet 4) to fitting on stage 7 air tube (I 0). Hand-tighten
(d)
Install orifice plate (42. sheet I) between flange of tube (40) and duct on front frame.
(e)
Using two bolts (43 ), secure tube (40) to the flange on front frame and to the support (41 ).
(f)
Torque bolts (43) to 105-115 lb in. (11.9-13.0 N·m).
(g)
Using 0.032 inch (0.81 mm) diameter lock wire, lock-wire bolts (43) using the double-strand method
(h)
Torque coupling nut on tube (40) to 900-1100 lb in. (101.7-124.3 N·m).
(i)
Install and position two cushioned clamps (52, sheet 3) onto tube (40) at locations shown.
(4.3-4.7 N·m).
(WP007 00).
coupling nut.
(WP 007 00).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 22
(j)
Using two bolts (46) and nuts (49). secure two cushioned clamps (52) to cushioned clamps (53) on
air regulator valve tube (55). Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
10.
REGULATOR VALVE AFT AIR TIJBE (G03/-G04/-G05 onlv).
a.
Remove regulator valve aft air tube (47. figure I. sheet 3) as follows:
(I)
Remove bolt (46) and nut (49) that secure cushioned clamp (48) to bracket (74) on transition
casing-to-LPT flange.
(2) Using two wrenches. disconnect coupling nuts on tube (47) from fitting on turbine transition casing and
from regulator valve forward air tube (50).
(3)
b.
Remove tube (47). Remove clamp (48) from tube.
Install aft air tube (47) as follows:
(I)
Install and position cushioned clamp (48) onto aft air tube (47) at location shown.
(2)
Connect coupling nuts on aft air tube (47) to fitting on forward air tube (50) and to fitting on turbine transition casing. Hand-tighten coupling nuts.
(3) Using bolt (46) and nut (49). secure cushioned clamp (48) to bracket (74) on transition
casing-to-LPT flange. Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(4) Torque coupling nut on aft air tube (47) to fitting on turbine transition casing to 90-100 lb in.
(I 0.2-11.3 N·m).
(5)
(15.3-17.5 N·m).
11.
Torque coupling nut on aft air tube (47) to fitting on forward air tube (50) to 135-155 lb in.
REGULATOR VALVE FORWARD AIR TIJBE (G03/-G04/-GOS ONLY).
a.
Remove regulator valve forward air tube (50. figure I. sheet 3) as follows:
(I) Remove two bolts (46) and nuts (49) that secure cushioned clamps (51) to cushioned clamps (52) on
stage 7 air tube (I 0).
(2) Remove bolt (46) and nut (49) that secure cushioned clamp (51) on tube (50). to cushioned clamp (51) on
C-sump forward tube (2).
(3)
Using two wrenches. disconnect coupling nut on regulator valve aft air tube (47) from fitting on tube (50).
(4)
Using two wrenches. disconnect coupling nut on tube (50) from B-sump regulator valve (56).
(5)
Remove grommet (75) from rear main mount ring (37).
(6)
Slide tube (50) from ring (37).
(7)
Remove three cushioned clamps (51) from tube (50).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
b.
Page 23
Install regulator valve forward air tube (50) as follows:
(I)
Install and position three cushioned clamps (51) onto tube (50) at locations shown.
(2)
Position tube (50) as shown. Slide one end of tube through hole in rear main mount ring (37).
(3)
Install grommet (75) into ring (37).
(4)
Connect coupling nut on tube (50). to fitting on B-sump regulator valve (56). Hand-tighten coupling nut.
(5)
Connect coupling nut on aft air tube (47) to fitting on tube (50). Hand-tighten coupling nut.
(6) Using two bolts (46) and nuts (49), secure two cushioned clamps (51) to cushioned clamps (52) on stage 7
air tube (10). Torque nuts to 38-42lb in. (4.3-4.7 N·m).
(7) Using bolt (46) and nut (49), secure cushioned clamp (51) on tube (50). to cushioned clamp (51) on
C-sump forward tube (2). Torque nut to 38-42lb in. (4.3-4.7 N·m).
12.
(8)
Torque coupling nut on tube (50) to 135-155lb in. (15.3-17.5 N·m).
(9)
Torque coupling nut on aft air tube (47) to 135-155 lb in. ( 15.3-17.5 N·m).
STAGE 7 REGULATOR AIR TUBE (G03/-G04/-G05/-G06 only).
a.
Remove stage 7 regulator air tube (59. figure I, sheet 3) as follows:
(I) On L32119G05 configuration. remove bolt (66) and nut (67) that secure cushioned clamp (68) to cushioned clamp (69) on stage 7 air tube (10).
(2) Using two wrenches, disconnect coupling nuts on tube (59) from fitting on stage 7 air tube (I 0) and from
B-sump regulator valve (56).
b.
(3)
Remove tube (59).
(4)
On L32119G05 configuration, remove clamp (68) from tube (59).
Install stage 7 regulator air tube (59) as follows:
(I)
On L32119G05 configuration, install clamp (68) onto tube (59) as shown.
(2) Connect coupling nuts on tube (59) to fitting on stage 7 air tube (I 0) and to B-sump regulator valve (56).
Hand-tighten coupling nuts.
(3) On L32119G05 configuration. install bolt (66) and nut (67) to secure cushioned clamp (68) to cushioned
clamp (69) on tube (10). Torque nut to 38-42 lb in. (4.3-4.7 N·m).
(4)
Torquecouplingnutsontube(59)to 135-1551bin.(15.3-17.5 N·m).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
13.
Page 24
B-SUMP OIL 1lJBE (G03/-G04/-G05/-G06 only).
a.
Remove B-sump oil tube (58, figure I, sheet 3) as follows:
(I)
Remove bolt (46) and nut (49) that secure cushioned clamp (57) to cushioned clamp (52) on A-sump pressure valve air metal tube ( 18).
(2) Using two wrenches. disconnect coupling nuts on oil tube (58) from fitting on combustion chamber and
from B-sump regulator valve (56).
b.
(3)
Remove oil tube (58).
(4)
Remove cushioned clamp (57) from tube.
Install B-sump oil tube (58) as follows:
(I)
Install and position cushioned clamp (57) onto oil tube (58) at location shown.
(2) Connect coupling nuts on tube (58) to fitting on combustion chamber and to B-sump regulator valve (56).
Hand-tighten coupling nuts.
(3)
Using bolt (46) and nut (49), secure cushioned clamp (57) to cushioned clamp (52) on tube (18). Torque
nut to 38-42 lb in. (4.3-4.7 N·m).
(4)
14.
Torque coupling nuts on tube (58) to 650-770 lb in. (73.4-87.0 N·m).
AIR REGULA TOR VALVE 1lJBE (G03/-G04/-G05/-G06 only).
a.
Remove air regulator valve tube (55. figure I, sheet 3) as follows:
(I) On L32119G03 and G04 configuration. remove three bolts (46) and nuts (49) that secure cushioned
clamps (53) to cushioned clamps (52) on stage 7 balance piston air tube (40).
(2) On L32119G05 and G06 configurations. remove two bolts (46) and nuts (49) that secure cushioned
clamps (53) to cushioned clamps (52) on stage 7 balance piston air tube (40).
(3)
Using two wrenches, disconnect coupling nuts on tube (55) from B-sump regulator valve (56) and B-sump
vent tee (54) on front frame.
b.
(4)
Remove tube (55).
(5)
Remove three cushioned clamps (53) from tube (55).
Install air regulator valve tube (55) as follows:
(I)
locations shown.
(2)
On L32119G03 and G04 configurations, install and position three cushioned clamps (53) onto tube (55) at
On L32119G05 and G06 configurations, install two cushioned clamps (53) onto tube (55) at locations
shown.
(3)
Position tube (55) as shown. Connect coupling nuts to B-sump regulator valve (56) and to B-sump vent
tee (54) on front frame. Hand-tighten coupling nuts.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 25
(4) On L32119G03 and G04 configurations. install three bolts (46) and nuts (49) to secure three cushioned
clamps (53) to cushioned clamps (52) on air tube (40). Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(5) On L32119G05 and G06 configurations. install two bolts (46) and nuts (59) to secure two cushioned
clamps (53) to cushioned clamps (52) on air tube (40). Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
(6)
15.
Torque coupling nuts on tube (55) to 650-770 lb in. (73.4-87.0 N·m).
STAGE 7 VALVE AIR TUBE (G05/-G06 Only).
a.
Remove stage 7 valve air tube (64, figure I, sheet 4) as follows:
(I)
Remove two bolts (60) and nuts (61) that secure cushioned clamps (63 ). on tube (64) to cushioned
clamps (62) on stage 7 air tube (I 0).
b.
(2)
Remove two bolts (12) and nuts (13) that connect tube (64) to pressure regulating valve assembly (31 ).
(3)
Remove four bolts (76) and nuts (77) that connect tube (64) to compressor stator casing assembly (36).
(4)
Remove tube (64).
(5)
Remove clamps (63) from tube (64).
(6)
Remove and discard gaskets (17 and 78).
Install stage 7 valve air tube (64) as follows:
(I)
Install two clamps (63) onto stage 7 valve air tube (64) as shown.
(2)
Install new gasket (78) onto compressor stator casing assembly (36).
(3)
Position tube (64) onto casing assembly (36).
(4) Install four bolts (76) and nuts (77) to secure tube (64) and gasket (78) to casing assembly (36).
Tighten nut hand-tight.
I CAUTION:]
The mating flange of pressure regulating valve assembly
(31) that connects to the mating flange of tube (64) must not
have an alignment pin hole. If the flange has an alignment
pin hole. the valve assembly is installed incorrectly and may
fail during operation.
(5) Check the mating flange of valve assembly (31) to ensure that the flange does not have an alignment pin
hole. If flange has an alignment pin hole. remove and test valve assembly (para 19).
(6)
Install new gasket (17) onto pressure regulating valve assembly (31).
(7)
Install two bolts ( 12) and nuts (13) to secure tube (64) and gasket (17) to valve assembly (31 ). Tighten nuts
hand-tight.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 26
(8) Install two bolts (60) and nuts (61) to secure cushioned clamps (63). on tube (64) to cushioned clamps (62)
on stage 7 air tube (10). Torque nuts to 38-421b in. (4.3-4.7 N·m).
(9)
Torque four nuts (77) to 38-42 lb in. (4.3-4.7 N·m).
(10) Torque two nuts (13) to 38-421b in. (4.3-4.7 N·m).
16.
CLEANING OF TIJBES.
a.
Flush tubes in clean water. and air-dry them.
32
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
b.
Using dry cleaning solvent P-D-680. flush the external and internal surfaces of tubes.
c.
Rinse the external and internal surfaces of tubes with filtered water.
I WARNING I
Compressed Air
•
•
•
•
d.
17.
When using compressed air for any cooling, cleaning,
or drying operation, do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench. wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench. wear approved respirator and goggles.
Using dry. filtered compressed air. dry the tubes.
INSPECTION OF TIJBES.
Go to table I .
TABLE 1.
Inspect
a.
Usable Limits
INSPECTION OF TUBES
Max Repairable Limits
Corrective Action
Tubes for:
(I) Splits and cracks.
None allowed.
Not repairable.
Replace tube.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 10
31 May 2002
Page 27
TABLE 1.
Inspect
b.
c.
INSPECTION OF TUBES (Cont)
Usable Limits
Max Repairable Limits
Corrective Action
(2) Nicks, scratches,
gouges. and
chafing.
Any number. up to 0.008
inch (0.20 mm) deep. without high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
(3) Dents.
Dented area must not
exceed 20% of tube
diameter.
Not repairable.
Replace tube.
(4) Flattened area.
Outside diameter must not
be less than 3/4 of the original diameter.
Not repairable.
Replace tube.
(5) Distortion.
Any amount, if tube can be
installed without force.
Any amount.
Cold-work tube to make it
fit properly, without force
(WP 007 00). Cracks and
kinks are not allowed.
Pressure-test tube (para 18).
(I ) Cracks.
None allowed.
Not repairable.
Replace tube.
(2) Damaged corners.
Any amount, if a wrench
can be used.
Not repairable.
Replace tube.
(3) Nicks and burrs.
Any number, without high
metal.
Any number. with high
metal.
Using a fine abrasive stone,
remove high metal
(WP007 00).
(4) Damaged threads.
One-half of one thread
(cumulative), without high
metal.
Same as usable limits, with
high metal.
Using a bottoming tap,
chase threads.
(I) Cracks.
None allowed.
Not repairable.
Replace tube.
(2) Circumferential
nicks and
scratches, and
shiny, burnished
surfaces on the
seating surface.
Any number that cannot be
felt with a scriber having a
0.030 inch (0.76 mm) tip
radius, without high metal.
Same as usable limits, with
high metal.
Using a fine abrasive stone.
remove high metal
(WP 007 00). Pressure-test
tube (para 18).
(3) Axial nicks and
None allowed.
Any number.
Using a fine abrasive stone.
blend defect. maintaining
original contour
(WP 007 00). Pressure-test
tube (para 18 ).
Hex coupling nuts for:
Male fittings for:
scratches. and pits
on the seating
surface.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
021 10
31 May 2002
Page 28
TABLE 1.
Usable Limits
Inspect
(4) Damaged threads.
d.
Max Repairable Limits
scratches. ridges.
and pits on seating
surface.
(2) Nicks and gouges
on tube flare.
One-half of one thread
(cumulative). without high
metal.
Same as usable limits. with
high metal.
Using a die, chase threads.
Any number. if the defect
does not extend more than
half way across seating surface. without high metal.
Same as usable limits. with
high metal.
Using a fine abrasive stone.
blend defect. maintaining
original contour
(WP 007 00). Pressure-test
tube (para 18).
Any number. 0.010 inch
(0.25 mm) deep, without
high metal. if tube passes
the pressure test.
Same as usable limits. with
high metal.
Blend high metal
(WP 007 00). Pressure-test
tube (para 18).
None allowed.
Not repairable.
Replace tube.
Tube flare ferrules for:
(I) Cracks.
234
Penetrating Oil
f.
18.
Corrective Action
Female fittings for:
(I) Nicks. dents.
e.
INSPECTION OF TUBES (Cant)
(2) Adhesion to
coupling nuts.
Any amount, if nut turns
smoothly on ferrule.
Any amount. if the nut can
be worked free to turn
smoothly on ferrule.
Apply penetrating oil
VV-P-216 to the nut, and
work it free. Using a lintfree cloth. remove all traces
of penetrating oil.
Mating flanges for
flatness (hold flange
against a flat surface
and try to insert a
0.005 inch (0.13 mm)
shim).
Flange must be flat within
0.005 inch (0.13 mm).
Up to 25o/c of original flange
thickness can be reworked
to meet usable limits.
Rework flange to usable
limits by lapping, stoning.
or machining (if possible).
PRESSURE-lEST OF TIJBES.
Calibrating Fluid, MIL-C-7024
a.
21
Using calibrating fluid MIL-C-7024. flush tube thoroughly.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page29
I WARNING I
High-Pressure Testing
•
•
•
•
19.
High pressures used during testing may cause rupturing or bursting of faulty tubes and hoses. The result
could be serious injury.
To prevent injury, cover all tubes and hoses with a
suitable safety shield during testing.
When caps or plugs are used, be sure they arc securely
installed to prevent them from being blown out.
Be sure that pressures are bled off before exposing or
touching hoses or tubes.
b.
Restrict one end of tube. Using calibrating fluid MIL-C-7024, build up pressure to 200 psig ( 1379 kPa).
c.
Maintain pressure for a minimum of 2 minutes. If there is a pressure drop, replace tube.
d.
Thoroughly drain tube of excess fluid. Cap or plug open ends.
PRESSURE REGULATING VALVE ASSEMBLY (All Models).
a.
Remove pressure regulating valve assembly (31, figure I, sheet I) as follows:
(I)
On L32119GO I, G03, and G04 configuration, disconnect stage 7 air tube (I 0) per paragraph 5.
(2)
On L32119G05 and G06 configurations. disconnect stage 7 valve air tube (64) per paragraph 15.
(3)
metal tube (18).
(4)
b.
Remove two bolts (20) and nuts ( 19) that secure the valve assembly (31) to A-sump pressure valve air
Remove valve assembly (31 ). Remove and discard gaskets ( 17 and 21 ).
Test the valve assembly (see figure 2) as follows:
(I)
Using kit adapter 21 C5536, set up valve assembly for testing as shown in figure 2.
(2) Using the control valve, vary the inlet air pressure from 20 to 80 psig (138 to 552 kPa). The discharge
(regulated) air pressure must be maintained at 12.5-17.5 psig (86-121 kPa). without resonance or instability. Record the minimum and maximum discharge (regulated) air pressure.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
(3)
the following:
Page 30
If the discharge (regulated) air pressure is not maintained throughout the range of supply air pressure. do
(a)
Disassemble valve assembly (see figure 3) as follows:
I WARNING I
Handling Spring-Loaded Parts
To avoid injury. use care when removing valve cap (3).
because spring (5) is under compression.
I CAUTION I
The nuts (I) should he alternately loosened one turn at a
time. to avoid deformation of valve cap (3) as spring pressure is relieved.
I
Alternately loosen two nuts (I) from valve cap (3 ). until spring pressure is relieved.
2
Remove two nuts (I) and bolts (2) from valve cap (3).
NOTE
There may he more than one shim (4) between valve cap (3)
and spring (5).
(h)
3
Remove valve cap (3) and shim (4 ). Save shim for installation.
4
Remove spring (5) and retainer assembly (6).
5
Remove two nuts (I). bolts (2). and valve cover (7).
6
Remove valve piston (8) from valve body (9).
Clean the components of valve assembly as follows:
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
I
32
Flush the components of valve assembly with dry cleaning solvent P-D-680.
2
Using a soft-bristle brush soaked with dry cleaning solvent P-D-680, remove any debris that has
accumulated onto components.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
02110
GEK 99441
Page 31
31 May 2002
DISCHARGE AIR
REQUIREMENTS
...
•
AIR SUPPLY: SHOP AIR REGULATED BETHEEN
20 AND 80 PSIG (138-552 kPa) FOR AIR
FLOH FR(Jf 0.003 TO 0.007 LB/SEC.
(1.36-3.17 GRAMS/SEC.).
•
DISCHARGE SIDE: FITTED HITH AN ORIFICE RESTRICTION
(SEE VIEH A FOR DETAILS) •
VOLUME BETWEEN VALVE OOTLET AND ORIFICE
RESTRICTION KJST BE 20-40 aJBIC INCHES
(328-656 OJBIC CENTIMETERS).
•
GAGES: ACOJRATE HITHIN 11 OF FULL SCALE READING.
INLET AIR
PRESSURE REGULATING
VALVE ASSEMBLY
SECTION VIEW
CONTROL VALVE
OUTLET AIR GAGE
0-30 PSIG
C0-207 kPa>
INLET AIR GAGE
0-100 PSIG
(0-689 kPa>
PRESSURE
INLET _.,._....fiiH
REGULATING
VALVE
(SHOP AIR AT
AIR
FILTER
AMBIENT
TEMPERATURE)
<10 MICRON)
y
DISCHARGE AIR
12.5-17.5 PSIG
J--..1.--40RIFICE t---(-86--1112..,1 kPa)
CVIEH A)
TEST SETUP
(0.81)
0.020 (0.51)
r-0.113 (2.870)
----
_ _ _ _ _ _:......J.. 0.111 (2.819)
DIA
\
0.75 (19.1)
DIA MINIMUM
VIEW A
ALL DIMENSIONS ARE IN INCHES WITH
MIWMETERS IN PARENTHESES.
Figure 2.
1201106-00-A2A
Testing of Pressure Regulating Valve Assembly
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 32
BORE B
2
7
1
'
1. Nut
2.
3.
4.
5.
Bolt
Valve Cap
Shim
Spring
---------
---------.
6. Retainer Assembly
7. Valve Cover
8. Valve Piston
9. Valve Body
- -....
1201107-00-02
Figure 3.
3
Disassembly. Inspection, and Assembly of Pressure Regulating Valve Assembly
Flush the components of valve assembly with dry cleaning solvent P-D-680.
I WARNING I
Compressed Air
•
•
•
•
4
(c)
When using compressed air for any cooling, cleaning.
or drying operation, do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench, wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench, wear approved respirator and goggles.
Using dry_ filtered. low-velocity compressed air, dry the components of valve assembly.
Inspect components of valve assembly as instructed in table 2.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
02110
GEK 99441
Page 33
31 May 2002
TABLE 2.
INSPECTION OF PRESSURE REGULATING VALVE ASSEMBLY COMPONENTS
Inspect
a.
Usable Limits
Max Repairable Limits
Corrective Action
Valve hody (9. figure 3)
for:
(I) Cracks.
None allowed.
Not repairable.
Replace valve hody.
(2) Wear in hore A.
1.002 inches (25.45 mm)
maximum average diameter
(measured at three
locations).
Not repairable.
Replace valve hody.
(3) Wear in hore B.
0.502 inch (12.75 mm) maximum average diameter
(measured at three
locations).
Not repairable.
Replace valve hody.
(a) Bores A
and B.
None allowed.
Not repairable.
Replace valve hody.
(h) Other areas.
Any number, 0.016 inch
(0.41 mm) deep. without
high metal.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00).
(I) Cracks.
None allowed.
Not repairable.
Replace valve piston.
(2) Wear on
diameter C.
0.4955 inch (12.586 mm)
minimum average diameter
(measured at three
locations).
Not repairable.
Replace valve piston.
(3) Wear on
0.9955 inch (25.286 mm)
minimum average diameter
(measured at three
locations).
Not repairable.
Replace valve piston.
(a) Diameters C
and D.
None allowed.
Not repairable.
Replace valve piston.
(h) Other areas.
Any nu m her. 0.016 inch
(0.41 mm) deep, without
high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
None allowed.
Not repairable.
Replace spring.
(4) Nicks. dents. and
scratches in:
h.
Valve piston (8) for:
diameter D.
( 4)
c.
Nicks. dents, and
scratches on:
Spring (5) for:
(I) Cracks.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
GEK 99441
02110
Page 34
31 May 2002
TABLE 2.
INSPECTION OF PRESSURE REGULATING VALVE ASSEMBLY COMPONENTS (Cant)
Inspect
Usable Limits
(2) Rub marks on
coils.
Rub marks allowed up to
0.020 inch (0.51 mm) wide.
Not repairable.
Replace spring.
(3) Relaxation and
permanent set.
Length of spring must be
1.20-1.25 inches
(30.5-31.8 mm) in free state.
Not repairable.
Replace spring.
(4) Nicks. dents. and
Any number. 0.016 inch
(0.41 mm) deep. without
high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
(I) Cracks.
None allowed.
Not repairable.
Replace part.
(2) Nicks. dents. and
scratches.
Any number. 0.016 inch
(0.41 mm) deep. without
high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
scratches.
d.
Max Repairable Limits
Corrective Action
Valve cap (3 ). retainer
assembly (6). and valve
cover (7) for:
(d)
Assemble valve assembly (see figure 3) as follows:
I Install valve cover (7) onto valve body (9). Using two bolts (2) and nuts (I). secure valve cover.
Torque nuts to 25-30 lb in. (2.8-3.4 N·m).
2
Install valve piston (8) into valve body (9) until piston bottoms.
3
Insert the retainer assembly (6) into the recess of valve piston (8). so that the ball end faces the
4
Install spring (5) onto retainer assembly (6).
valve piston.
NOTE
•
•
The regulated pressure from the valve assembly is
determined by the spring preload. The shim
PN 2018Tl5POI (4) is used to set the preload.
Adding one shim (4) increases the output pressure
approximately 0.75 psi (5.2 kPa).
5
Using the test results recorded in step b.(2). change the number of shims (4) as required to adjust
the discharge air pressure within limits. If more than six shims are required to achieve correct discharge air pressure regulation. replace valve assembly. Return the replaced valve assembly to the vendor for repair.
6
Install the required shims (4) into the inner recess of valve cap (3 ).
7
Install valve cap (3) onto valve body (9). Using two bolts (2) and nuts (I). secure valve cap.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
31 May 2002
Page 35
CAUTION
The nuts (I) should be alternately tightened one turn at a
time, to avoid deformation of valve cap (3) as spring pressure increases.
8
Alternately tighten nuts (I) on valve cap (3).
9
Torque nuts (I) to 25-30 lb in. (2.8-3.4 N·m).
I 0 Re-test valve assembly.
c.
Install pressure regulating valve assembly (31, figure I. sheet I) as follows:
I CAUTION I
The mating flange of valve assembly (31) that will connect
with the mating flange of A-sump pressure valve air metal
tube (18) must have an alignment pin hole. If the flange
does not have an alignment pin hole. the valve assembly
will not be installed correctly and may fail during operation.
(I)
Position the valve assembly (31) so that the mating flange with the alignment pin hole faces the mating
flange of tube (18).
CAUTION
The alignment pin on mating flange of tube ( 18) must align
with the hole in gasket (21 ), and with the hole in mating
flange of valve assembly (31 ). Otherwise, leaks will occur.
(2) Install new gasket (21) between flanges of valve assembly (31) and tube (18). Be sure that the alignment
pin on tube aligns with hole in gasket and with alignment pin hole on flange of valve assembly.
(3) Using two bolts (20) (boltheads facing down) and nuts ( 19). secure flange of tube ( 18) to flange of valve
assembly (31 ). Torque nuts to 38-42 lb in. (4.3-4.7 N·m).
( 4)
On L32119GO I. G03, and G04 configurations. re-connect stage 7 air tube (I 0) to valve assembly (31) per
paragraph 5.
(5)
paragraph (15 ).
20.
On L32119G05 and G06 configuration, reconnect stage 7 valve air-tube (64) to valve assembly (31) per
B-SUMP REGULATOR VALVE fG03/-G04/-G05/-G06 only).
a.
Remove B-sump regulator valve (56. figure I, sheet 3) as follows:
(I) On L32119G03, G04, and G05 configurations, disconnect coupling nut on regulator valve forward
air tube (50) from valve (56).
(2)
Disconnect coupling nut on air regulator valve tube (55) from valve (56).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
02110
Page 36
31 May 2002
b.
(3)
Disconnect coupling nut on B-sump oil tube (58) from valve (56).
(4)
Disconnect coupling nut on stage 7 regulator air tube (59) from valve (56).
(5)
Remove valve (56).
Inspect B-sump regulator valve as instructed in table 3.
TABLE 3.
Inspect
a.
b.
INSPECTION OF B-SUMP REGULATOR VALVE
Usable Limits
Max Repairable Limits
Corrective Action
Valve body for:
(I) Cracks.
None allowed.
Not repairable.
Replace valve.
(2) Nicks, dents, and
scratches.
Any number. 0.016 inch
(0.41 mm) deep. without
high metal.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00).
Any number that cannot be
felt with a scriber having a
0.030 inch (0.76 mm) tip
radius. without high metal.
Same as usable limits, with
high metal.
(2) Axial nicks and
scratches, and pits
on the seating
surface.
None allowed.
Any number.
Using a fine abrasive stone,
blend defect, maintaining
original contour
(WP 007 00).
(3) Damaged threads.
One-half of one thread
(cumulative), without high
metal.
Same as usable limits, with
high metal.
Chase threads.
Fittings for:
(I) Circumferential
nicks and
scratches, and
shiny, burnished
surfaces on the
seating surface.
c.
. Using a fine abrasive stone,
remove high metal
(WP 007 00).
Install B-sump regulator valve (56) as follows:
(I)
Position valve (56) as shown.
(2) On L32119G03. G04, and G05 configurations. connect coupling nut on regulator valve forward air tube
(50) to valve (56). Hand-tighten coupling nut.
(3)
Connect coupling nut on air regulator valve tube (55) to valve (56). Hand-tighten coupling nut.
(4)
Connect coupling nut on B-sump oil tube (58) to valve (56). Hand-tighten coupling nut.
(5)
Connect coupling nut on stage 7 regulator air tube (59) to valve (56). Hand-tighten coupling nut.
(6) On L321 I 9G03. G04, and G05 configuration, torque coupling nuts on forward air tube (50) to
135-155lb in. (15.3-17.5 N·m).
(7)
Torque coupling nut on regulator airtube (59) to 90-100 lb in. (I 0.3-11.3 N·m ).
(8)
Torque coupling nuts on oil tube (58) and valve tube (55) to 650-770 lb in. (73.4-87.0 N·m).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
022 00
GEK 99441
31 May 2002
Page 1 of 4
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
WATER WASH HOSES AND SPRAY NOZZLES
REMOVAL AND INSTALLATION
(LEVEL 2 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Subject
Page No.
Consumable Materials ................................................................ .
Introduction ........................................................................ .
Support Equipment .................................................................. .
Water Wash Hoses and Spray Nozzles
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal .......................... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
I
1. INTRODUCTION. This work package provides instructions for removing and installing the water wash hoses and
spray nozzles from the front frame.
2.
SUPPORT EQUIPMENT.
None
3.
CONSUMABLE MATERIALS.
None
4.
REMOVAL.
a.
If applicable. disconnect customer-supplied hose from hose inlet tee (8. figure I) at the 5:30 o'clock position
(forward looking aft) under the front frame (6 ).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
022 00
GEK 99441
31 May 2002
Page2
e
I
I
I
7
"',,t/'1 1:5rt{
2
9
y
NO HOSE AT
LOCATION_/
nns
"'\
9
7
....
1
---e
1.
2.
3.
4.
5.
6.
7.
8.
9.
Water Wash Hose (Qty 8)
Nut (Qty 16)
Spray Nozzle (Qty 8)
Self-locking Nut
Washer
Front Frame
Plug (Qty 2)
Hose Inlet Tee
Port
12011 09-00-A2A
Figure I.
Removal and Installation of Water Wash Hoses and Spray Nozzles
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
022 00
GEK 99441
Page 3
31 May 2002
CAUTION
The five shortest water wash hoses (I) must not he disconnected from spray nozzles (3 ); otherwise. hoses will he
damaged.
NOTE
There are eight hoses (I ) around the circumference of the
front frame (6):
•
•
•
•
5.
One hose is 3.36 inches (85.3 mm) long
One hose is 8.75 inches (222.3 mm) long
Two hoses are 12.42 inches (315.5 mm) long each
Four hoses are 4.96 inches ( 126.0 mm) long each.
h.
Loosen nuts (2) from the longest hoses (I). Remove hoses from spray nozzles (3 ).
c.
Remove self-locking nuts (4) and washers (5) securing spray nozzles (3) to ports (9) in front frame (6).
d.
Loosen nuts (2) from the shortest hoses (I). Remove hoses from spray nozzles (3).
e.
Loosen two nuts (2) from hose inlet tee (8). Remove hose inlet tee.
f.
Remove nut (2) and plug (7) from two spray nozzles (3 ).
INSTALLATION.
a.
Install spray nozzles (3, figure I) into each port (9) on front frame (6 ).
h.
Using washers (5) and self-locking nuts (4), secure each spray nozzle (3). Torque nuts to 10-15lh in.
(1.1-1.7 N·m).
I CAUTION I
Do not over-torque nuts (4 ); otherwise, spray nozzles will
he damaged.
c.
Check washers (5) for looseness. If washers are loose. torque nuts (4) to 20 lh in. (2.3 N·m) maximum.
NOTE
•
•
The location of the spray nozzles (3) will determine
the size of the water wash hoses (I) to he installed
around the circumference of the front frame (6 ).
Between the 11 and I o'clock positions there will not
he a hose (I ). The end of the two spray nozzles (3) at
this location will he plugged.
d. Install plug (7) into each end of the two spray nozzles (3) between the 11 and I o'clock positions. Install nut (2)
onto each plug. Torque nuts to 5-10 lh in. (0.6-1.1 N·m).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
022 00
GEK 99441
Page4
31 May 2002
NOTE
The hose inlet tee (8) will be positioned between the two
hoses (I) at the 5:30 o'clock position (forward looking aft)
under the front frame (6).
e.
Install the shortest hoses (I) into spray nozzles (3) and into hose inlet tee (8).
f.
If nuts (2) were removed from hoses (I), slide nuts onto hoses and hand-tighten nuts onto spray nozzles (3) and
hose inlet tee (8).
g.
Install the remaining hoses (I) into spray nozzles (3) and into hose inlet tee (8).
h.
Torque all nuts (2) to 5-l 0 lb in. (0.6-1.1 N·m).
1.
If applicable, connect customer-supplied hose onto hose inlet tee (8).
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
023 00
GEK 99441
Page 1 of 34
31 May 2002
LM500 GAS TURBINE
Operating Instructions and On-Site Maintenance
TECHNICAL PROCEDURES
IGNITION SYSTEM COMPONENTS
REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
(LEVEL 2 MAINTENANCE)
Effectivity:
L32119GO 1/-G03/-G04/
-G05/-G06
L32119G02
MARINE GAS TURBINE
INDUSTRIAL GAS TURBINE
Alphabetical Index
Page No.
Subject
Consumable Materials ................................................................
Exciter Bracket Assembly (G05/-G06) ...................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Igniter Plugs and Bushings ............................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Ignition Exciter. .....................................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Ignition Leads .......................................................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Repair ..........................................................................
Introduction ........................................................................
Support Beam Assembly (L32119GOI/-G02/-G03/-G04) ....................................
Cleaning ........................................................................
Inspection .......................................................................
Installation ......................................................................
Removal ........................................................................
Support Equipment ..................................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
2
12
12
14
15
12
29
31
34
29
3
6
7
8
3
15
20
22
26
15
23
I
9
9
11
12
9
2
1. INTRODUCTION. This work package provides instructions for removing, inspecting. cleaning, and installing ignition
system components.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
2.
Page2
SUPPORT EQUIPMENT.
Support Equipment
Part No.
Nomenclature
8600A
Voltmeter. Digital
Iron, Soldering (200-WATT)
3.
CONSUMABLE MATERIALS.
NOTE
Equivalent materials approved by GE Aircraft Engines may
be substituted for items listed.
Consumable Materials
Description
Manufacturer
Acetone (0-A-51)
Local Purchase
Alcohol, Isopropyl (TT-I-735)
Local Purchase
Brush, Soft-Bristle
Local Purchase
Brush, Stiff-Bristle
Local Purchase
Caps, Protective
Protective Closures Co .. Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Cloth, Lint-Free
Local Purchase
Copper Strip (Electrolytic or Grade OFHC)
0.025 inch (0.64 mm) thick
Local Purchase
Lockwire. 0.020 inch (0.51 mm) diameter
Local Purchase
Solder, Resin Core
Local Purchase
Solvent, Dry Cleaning (Stoddard Solvent) (P-D-680)
Local Purchase
Solvent, Miller-Stephenson (MS-160)
Miller-Stephenson
Chemical Co., Inc.
George Washington Hwy.
P.O. Box 950
Danbury, CT 06810
USA
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page3
Consumable Materials (Cont)
4.
Description
Manufacturer
Tape, Silicone (PN 3003M70POI)
GE Aircraft Engines
I Neumann Way
Box 156301
Cincinnati, OH 45215
USA
IGNITION EXCITER
a.
Removal.
(I)
Remove lock wire from coupling nuts that connect ignition leads (2. 6. figure I. sheet I) to ignition
exciter (I).
I WARNING I
Disconnecting Ignition Leads
•
•
High voltage may be present. Contact with center
conductor of electrical cable or center electrode of
igniter plug will cause electric shock if the bleed
resistors inside ignition unit have failed.
Before removing igniter plug. be sure that discharge
connector is grounded.
(2)
Disconnect ignition leads (2, 6) from ignition exciter (I).
(3)
Remove lockwire from connector on electrical cable (5).
(4)
Disconnect electrical cable (5) from ignition exciter (I).
(5)
Remove and discard sealing disk (3) and packing (4) from electrical cable (5).
(6) On L32119GO I, G02. G03, and G04 configurations, loosen four bolts (7) until ignition exciter (I) can be
removed from support beam assembly (12). Do not remove bolts from isolators ( 11 ).
(7)
Remove ignition exciter (I) from support beam assembly (12).
(8) On L32119G05 and G06 configurations, loosen four bolts (7, sheet 2) until ignition exciter (I) can be
removed from exciter bracket ( 16).
(9)
Remove ignition exciter from exciter bracket ( 16 ).
(I 0) If ignition exciter (I) is to be replaced, remove the following:
(a)
Remove four bolts (7).
(b)
Remove ferrules (I 0, 15) and isolators ( 11 ).
(c)
Remove bolt (14) and self-locking nut (8).
(d)
Remove grounding strap (9).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
Page4
31 May 2002
,,
I
L32119G01/-G02/-G03/-G04
Figure I.
1.
2.
3.
4.
5.
Ignition Exciter
Ignition Lead
Sealing Disk
Packing
Electrical Cable
(Customer Supplied)
6. Ignition Lead
7. Bolt
8. Self-Locking Nut
9. Grounding Strap
10. Ferrule
11. Isolator
12. Support Beam Assembly
13. Nut Plate
14. Bolt
15. Ferrule
16. Exciter Bracket
1201110-00-A2A
Removal and Installation of Ignition Exciter (Sheet I of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
PageS
L32119G05/-G06
1202555-0G-A2A
Figure I.
Removal and Installation of Ignition Exciter (Sheet 2 of 2)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
b.
Page6
Cleaning.
(I)
If electrical connectors are contaminated. clean connectors as follows:
Isopropyl Alcohol, TT-1-735
11
(a) Using isopropyl alcohol TT-1-735 and holding spray nozzle 4-6 inches (100-150 mm) away. spray
electrical connector to loosen contaminants.
I WARNING I
Compressed Air
•
•
•
•
When using compressed air for any cooling. cleaning.
or drying operation. do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench, wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench. wear approved respirator and goggles.
(b) Drain excess liquid immediately. Blow-dry with low velocity 15 psig (I 03 kPa), dry, filtered compressed air. Allow connector seals to dry for I hour minimum.
(c)
(2)
Install protective caps on electrical connectors.
Clean external surfaces of ignition exciter as follows:
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
(a)
Using a lint-free cloth saturated with dry cleaning solvent P-D-680. remove grease, dirt, and oil
(b)
Using filtered. dry compressed air, blow-dry external surfaces of ignition exciter.
deposits.
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
Page7
31 May 2002
c.
Inspection. Go to table I.
TABLE 1.
Inspect
a.
b.
Usable Limits
Max Repairable Limits
Corrective Action
Case (see figure 2) for:
(I ) Cracks.
None allowed.
Not repairable.
Replace ignition exciter.
(2) Nicks and
scratches.
Any number, if defect does
not penetrate case.
Not repairable.
Replace ignition exciter.
(3) Dents and bulges.
Any number, if there is no
loss of hermetic seal or
structural integrity.
Not repairable.
Replace ignition exciter.
(4) Chipped or flaked
paint.
Any amount.
Not applicable.
Not applicable.
Any number. without high
metaL if connector can be
installed to mating connector without cross-threading.
Same as usable limits, with
high metal.
Remove high metal
(WP 007 00) and blend to
adjacent contour. Check
alignment with mating
connector.
(2) Damaged threads.
Any number, without high
metal, if connector can be
installed to mating connector without cross-threading.
Same as usable limits, with
high metal.
Chase threads.
(3) Bent pins.
None allowed.
Up to 1/8 inch (3.2 mm)
out-of-position.
Straighten pin. Check
alignment with mating
connector.
(4) Cracked or missing
insulation.
Not allowed.
Not repairable.
Replace ignition exciter.
(5) Contamination or
moisture.
Not allowed.
Any amount.
Clean connectors (para b).
(a) Pin A to
ground.
43 to 53 ohms.
Not repairable.
Replace ignition exciter.
(b) Pin C to
ground.
43 to 53 ohms.
Not repairable.
Replace ignition exciter.
(c) Pin B to
ground.
There must be continuity.
Not repairable.
Replace ignition exciter.
Input and output
connectors for:
(I) Burrs. nicks. and
dents.
c.
INSPECTION OF IGNITION EXCITER
Connector resistance.
using digital voltmeter
8600A, at:
(I) Input connector:
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GEK 99441
023 00
31 May 2002
Page 8
TABLE 1.
Inspect
Usable Limits
(2) Output connector
pins to case.
d.
INSPECTION OF IGNITION EXCITER (Cant)
540 to 660 ohms.
Max Repairable Limits
Not repairable.
Corrective Action
Replace ignition exciter.
Installation.
(I)
If the ignition exciter (I, figure I, sheet I) was replaced. install the following parts onto the replacement
ignition exciter:
(a)
Install each of the four isolators ( 11) into holes on ignition exciter (I).
(b)
Install ferrules (I 0, 15) on both sides of isolators ( 11 ).
(c)
Install bolt (7) and one end of grounding strap (9) at location shown on ignition exciter (I).
(d)
Install remaining three bolts (7) through ferrules and isolators.
(e)
Using bolt (14) and self-locking nut (8). secure other end of grounding strap (9) to ignition
exciter (I). Torque nut to 24-27 lb in. (2.7-3.1 N·m).
(2) On L32119G01. G02. G03. and G04 configurations. install ignition exciter (I) onto support beam assembly ( 12) as shown. Thread bolts (7) into nut plates ( 13) on support beam assembly. Torque bolts to 24-27 lb in. (2.7-3.1 N·m).
CASE
OUTPUT CONNECTORS
1201202-00-02
Figure 2.
Inspection of Ignition Exciter
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
Page9
31 May 2002
(3)
(4)
(2.7-3.1 N·m).
On L32119G05 and G06 configurations install ignition exciter (I. sheet 2) onto exciter bracket (16).
Install four bolts (7) to secure ignition exciter (I) to exciter bracket ( 16 ). Torque bolts to 24-27 lb in.
CAUTION
•
•
Do not use tools to install connector of electrical
cable (5). If difficulty is encountered in connecting
connectors. check cable connectors and mating connectors for crossed threads. bent pins. and damaged
keys or slots.
Do not lubricate electrical connectors or packings.
(5) Install sealing disk (3) onto the center connector on ignition exciter (I). Install packing (4) onto connector
of electrical cable (5 ). Connect electrical cable to center connector of ignition exciter.
I CAUTION I
Ignition lead connectors can be easily distorted. To avoid
damaging connectors. use a box-end crowfoot wrench when
torquing connectors.
(6) Connect two ignition leads (2. 6) to ignition exciter (I). Torque coupling nuts on ignition leads to
95-120 lb in. (I 0.7-13.6 N·m).
(7)
Using 0.020 inch (0.51 mm) diameter lockwire. lock-wire ignition leads (2. 6) and electrical cable (5)
using the double-strand method (WP 007 00).
5.
SUPPORT BEAM ASSEMBLY (L32119G01/-G02/-G03/-G04).
a.
Removal.
(I)
Remove ignition exciter (para 4. a).
(2) Remove four self-locking nuts (3. figure 3). eight t1at washers (2). and four bolts (I) from front frame-tocompressor casing t1ange.
b.
(3)
Remove five self-locking nuts (9). and bolts (8) from hinge (7) at compressor-to-combustion frame flange.
(4)
Remove support beam assembly (6).
Cleaning.
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
(I)
Using a lint-free cloth saturated with dry cleaning solvent P-D-680. remove grease. dirt, and oil deposits
from support beam assembly.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 10
COMPRESSOR-TO-COMBUSTION
FRAME FLANGE
FRONT FRAME-TO-COMPRESSOR
CASING FLANGE
LEGEND:
1.
2.
3.
4.
5.
BOLT
FLAT WASHER
SELF-LOCKING NUT
RIVET
NUT PLATE
6.
7.
8.
9.
SUPPORT BEAM
HINGE
BOLT
SELF-LOCKING NUT
L32119GOI/-G02/-G03/-G04
1201111-00-A2A
Figure 3.
Removal. Inspection. and Installation of Support Beam Assembly
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 11
I WARNING I
Compressed Air
•
•
•
•
(2)
c.
When using compressed air for any cooling, cleaning,
or drying operation, do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench, wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench, wear approved respirator and goggles.
Using dry, filtered compressed air, blow-dry support beam assembly.
Inspection. Go to table 2.
TABLE 2.
Inspect
a.
INSPECTION OF SUPPORT BEAM ASSEMBLY
Usable Limits
Max Repairable Limits
Support beam assembly
(6, figure 3) for:
None allowed.
Not repairable.
Replace support beam
assembly.
(2) Distortion.
Any amount, if support
beam assembly can be
installed normally to mating parts.
Same as usable limits.
Cold-work (WP 007 00)
support beam assembly.
Using a I OX magnifying
glass, inspect for cracks. No
cracks are allowed.
(3) Nicks, dents, and
1/32 inch (0.8 mm) deep,
without high metal.
Same as usable limits, with
high metal.
Remove high metal
(WP007 00).
Usable if mating bolt cannot
be threaded through nut by
hand.
Not repairable.
Remove nut plate (5) by
drilling head of rivets (4)
using 1/16 inch (1.6 mm)
drill followed by a 3/32 inch
(2.4 mm) drill. Remove old
rivets and install new nut
plate and new rivets.
(I) Cracks and
buckling.
scratches.
b.
Corrective Action
Nut plate (5) for loss of
self-locking feature or
damaged threads.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
d.
Page 12
Installation.
(I)
Position support beam assembly (6. figure 3 ). as shown. between the front frame-to-compressor casing
flange and compressor-to-combustion frame flange.
(2) Using five bolts (8), and self-locking nuts (9). secure hinge (7) of support beam
assembly (6) onto aft end of compressor-to-combustion frame flange.
(3)
Using four bolts (I), eight flat washers (2 ). and four self-locking nuts (3 ), secure the forward end of support beam assembly (6) onto aft end of front frame-to-compressor casing flange.
6.
(4)
Torque self-locking nuts (9) to 160-170 lb in. (18.1-19.2 N·m).
(5)
Torque self-locking nuts (3) to 105-115 lb in. (11.9-13.0 N ·m).
(6)
Install ignition exciter (para 4. d).
EXCITER BRACKET ASSEMBLY (L32119G05/-G06).
a.
Removal
(I)
Remove ignition exciter (para 4.a).
(2)
Remove three bolts (I. figure 4 ), nuts (2). and washers (3) from front frame-to-compressor casing flange.
(3)
Remove bolt (4 ). inside spacer bushing (5 ). and outside spacer bushing (6) from upper support beam
(4)
Remove exciter bracket assembly (7).
assembly.
b.
Cleaning.
Dry Cleaning Solvent
(Stoddard Solvent), P-D-680
32
(I)
Using a lint-free cloth saturated with dry cleaning solvent P-D-680. remove grease. dirt, and oil deposits
from exciter bracket assembly.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 13
LEGEND:
1. BOLT
2.
3.
4.
5.
6.
7.
NUT
WASHER
BOLT
INSIDE SPACER BUSHING
OUTSIDE SPACER BUSHING
EXCITER BRACKET ASSEMBLY
I
I
I
I
I
UPPER SUPPORT
BEAM ASSEMBLY
FRAME-TO-COMPRESSOR
CASING FLANGE
L32119G05/-G06
1202558-00-A2A
Figure 4.
RemovaL Inspection and Installation of Exciter Bracket
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 14
I WARNING I
Compressed Air
•
•
•
•
(2)
c.
Using dry, filtered compressed air. blow-dry exciter bracket assembly.
Inspection. Go to table 3.
TABLE 3.
Inspect
a.
When using compressed air for any cooling, cleaning.
or drying operation. do not exceed 30 psig (207 kPa)
at the nozzle.
Eyes can be permanently damaged by contact with
liquid or large particles propelled by compressed air.
Inhalation of air-blown particles or solvent vapor can
damage lungs.
When using air for cleaning at an air-exhausted workbench, wear approved goggles or face shield.
When using air for cleaning at an unexhausted workbench, wear approved respirator and goggles.
INSPECTION OF EXCITER BRACKET ASSEMBLY
Usable Limits
Max Repairable Limits
Exciter bracket
assembly (7, figure 4)
for:
(I) Cracks and
None allowed.
Not repairable.
Replace exciter bracket
assembly.
(2) Distortion.
Any amount, if exciter
bracket assembly can be
installed normally to mating parts.
Same as usable limits.
Cold-work exciter bracket
assembly (WP 007 00).
Using a !OX magnifying
glass. inspect for cracks. No
cracks are allowed.
(3) Nicks. dents, and
1132 inch (0.8 mm) deep.
without high metal.
Same as usable limits. with
high metal.
Remove high metal
(WP 007 00).
Usable if mating bolt cannot
be threaded through nut by
hand.
Not repairable.
Remove nut plate by drilling
head of rivets using
1116 inch (1.6 mm) drill
followed by a 3/32 inch
(2.4 mm) drill. Remove old
rivets and install new nut
plate and new rivets.
buckling.
scratches.
b.
Corrective Action
Nut plates for loss of
self-locking feature or
damaged threads.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
d.
Page 15
Installation.
(I)
Position exciter bracket assembly (7, figure 4) as shown. between front frame-to-compressor casing flange
and upper support beam assembly.
(2)
Install bolt (4 ), inside spacer bushing (5 ), and outside spacer bushing (6) to secure exciter bracket assembly
(7) to upper support beam assembly. Tight bolt hand-tight.
(3)
Install three bolts (I), nuts (2), and washers (3) to secure exciter bracket assembly (7) to front frame-tocompressor casing flange. Torque nuts to 105-115 lb in. ( 11.9-13.0 N·m).
(4)
7.
Torque bolt (4) to 55-70 lb in. (6.2-7.9 N·m).
IGNITION LEADS.
a.
Removal.
(I)
On L32119GO I, G02. G03. and G04 configurations remove ignition leads as follows:
(a)
Remove lockwire from coupling nuts that connect ignition leads (2, 3, figure 5. sheet I) to ignition
exciter (I).
I WARNING I
Disconnecting Ignition Leads
•
•
(b)
High voltage may be present. Contact with center
conductor of electrical cable or center electrode of
igniter plug will cause electric shock if the bleed
resistors inside ignition unit have failed.
Before removing igniter plug, be sure that discharge
connector is grounded.
Disconnect ignition leads (2. 3) from ignition exciter (I).
(c) Remove lock wire from coupling nuts that connect ignition leads (2, 3) to igniter plugs ( 19, 17) at the
2 and I 0 o'clock positions on combustion chamber frame (18).
(d)
Disconnect ignition leads (2. 3) from igniter plugs ( 19. 17).
(e)
(Marine Only). Remove self-locking nut (4) and bolt (7) from cushioned clamps (5, 6).
(t)
Remove self-locking nut (9) and bolt (I 0) from cushioned clamp (8).
(g)
Remove self-locking nut (13) and bolt (11) from cushioned clamps (12).
(h)
Remove ignition lead (2).
(i)
Remove self-locking nut (16) and bolt (14) from cushioned clamp (15).
(j)
Remove ignition lead (3).
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
1.1GNITION EXCITER
2. IGNITION LEAD
3. IGNITION LEAD
4. SELF-LOCKING NUT
5. CUSHIONED CLAMP
6. CUSHIONED CLAMP
?.BOLT
8. CUSHIONED CLAMP
9. SELF-LOCKING NUT
10. BOLT
11. BOLT
12. CUSHIONED CLAMP
13. SELF-LOCKING NUT
14. BOLT
15. CUSHIONED CLAMP
16. SELF-LOCKING NUT
17.1GNITER PLUG
Page 16
19.1GNITER PLUG
20. SELF-LOCKING NUT
21. BOLT
22. CUSHIONED CLAMP
23. CUSHIONED CLAMP
24. SELF-LOCKING NUT
25. BOLT
26. CUSHIONED CLAMP
27. HARNESS SUPPORT BRACKET
28. SELF-LOCKING NUT
29. BOLT
30. CUSHIONED CLAMP
31. ANGLE BRACKET
32. BOLT
33. CUSHIONED CLAMP
L32119G01!-G02/-G03/-G04
1201203-00-A2A
Figure 5.
Removal and Installation of Ignition Leads (Sheet I of:\)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 17
Q
TOP VIEW
FORWARD
L32119G05
1202556-00-A2A
Figure 5.
Removal and Installation of Ignition Leads (Sheet 2 of 3)
GE PROPRIETARY INFORMATION -Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page18
3
REF
G
TOP VIEW
FORWARD
L32119G06
1202557-00-A2A
Figure 5.
Removal and Installation of Ignition Leads (Sheet 3 of3)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
(2)
Page 19
On L32119G05 configuration remove ignition leads as follows:
(a)
Remove lockwire from coupling nuts that connect ignition leads (2, 3, figure 5, sheet 2) to ignition
exciter (I).
I WARNING I
Disconnecting Ignition Leads
•
•
(b)
High voltage may be present. Contact with center
conductor of electrical cable or center electrode of
igniter plug will cause electric shock if the bleed
resistors inside ignition unit have failed.
Before removing igniter plug, be sure that discharge
connector is grounded.
Disconnect ignition leads (2. 3) from ignition exciter (I).
(c) Remove lock wire from coupling nuts that connect ignition leads (2, 3) to igniter plugs ( 19. 17) at the
2 and I 0 o'clock positions on combustion chamber frame ( 18 ).
(d)
Disconnect ignition leads (2, 3) from igniter plugs (19, 17).
(e)
Remove two self-locking nuts (20, sheet 2) and bolts (21) from cushioned clamps (22. 23 ).
(f)
Remove self-locking nut (24) and bolt (25) from cushioned clamps (26) securing ignition leads (2, 3)
to harness support bracket (27).
(g)
Remove self-locking nut (28) and bolt (29) from cushioned clamp (30) securing ignition lead (2) to
(h)
Remove ignition lead (2).
(i)
Remove bolt (32) from cushioned clamp (33).
(j)
Remove ignition lead (3).
angle bracket (31 ).
(3)
On L32119G06 Configuration. remove ignition leads as follows:
(a)
Remove Jockwire from coupling nuts that connect ignition leads (2, 3. figure 5, sheet 3) to ignition
exciter (I).
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
023 00
GEK 99441
31 May 2002
Page 20
I WARNING I
Disconnecting Ignition Leads
•
•
(b)
High voltage may be present. Contact with center
conductor of electrical cable or center electrode of
igniter plug will cause electric shock if the bleed
resistors inside ignition unit have failed.
Before removing igniter plug. be sure that discharge
connector is grounded.
Disconnect ignition leads (2. 3) from ignition exciter (I).
(c) Remove lockwire from coupling nuts that connect ignition leads (2. 3) to igniter plugs ( 19. 17) at the
2 and I 0 o ·clock positions on combustion chamber frame ( 18 ).
(d)
Disconnect ignition leads (2. 3) from igniter plugs (19. 17).
Remove self-locking nut (24) and bolt (25) from cushioned clamps (26) securing ignition leads (2, 3)
(e)
to harness support bracket (27 ).
(f)
Remove self-locking nut (28) and bolt (29) from cushioned clamp (30) securing ignition lead (2) to
(g)
Remove ignition lead (2).
(h)
Remove bolt (32) from cushioned clamp (33 ).
(i)
Remove ignition lead (3).
angle bracket (31 ).
b.
Cleaning.
Miller-Stephenson Solvent
MS-160 (Or Freon, TP-35)
85
(I)
Using a stiff-bristle brush soaked with Miller-Stephenson solvent (MS-160), clean the Tetlon chafing
sleeve (see figure 6) of ignition lead.
(2)
Using a soft-bristle brush soaked with solvent MS-160. clean ceramic insulator, socket contact. and Tetlon
bushing.
GE PROPRIETARY INFORMATION- Subject to the restrictions on the cover or first page.
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